System and method of active torch marker control

ABSTRACT

A welding system includes one or more cameras and a controller coupled to the one or more cameras. The one or more cameras are configured to detect a plurality of sets of visual markers of a welding device, where each each set is oriented in a respective marker direction. The controller is configured to determine one or more marker directions of one or more respective sets of visual markers based on a detected set of visual markers, to select one of the sets of visual markers as a tracked set of visual markers based at least in part on a determined marker direction of the tracked set of visual markers, to associate a rigid body model to the tracked set of visual markers, and to determine a position and an orientation of the welding device based on the associated rigid body model of the tracked set of visual markers.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from and the benefit of U.S.Provisional Application Ser. No. 62/075,701, entitled “SYSTEM AND METHODOF ACTIVE TORCH MARKER CONTROL,” filed Nov. 5, 2014, which is herebyincorporated by reference in its entirety for all purposes.

BACKGROUND

The invention relates generally to welding and, more particularly, to awelding system that may be used for monitoring a weld environment andmanaging welding data associated with the weld environment, such aswelding data collected from the weld environment during and/or precedingwelding.

Welding is a process that has increasingly become utilized in variousindustries and applications. Such processes may be automated in certaincontexts, although a large number of applications continue to exist formanual welding operations. In both cases, such welding operations relyon a variety of types of equipment to ensure the supply of weldingconsumables (e.g., wire feed, shielding gas, etc.) is provided to theweld in appropriate amounts at the desired time.

In preparation for performing manual welding operations, weldingoperators may be trained using a welding system (e.g., a weldingtraining system). The welding system may be designed to train weldingoperators with the proper techniques for performing various weldingoperations. Certain welding systems may use various training methods. Asmay be appreciated, these training systems may be expensive to acquireand operate. Accordingly, welding training institutions may only acquirea limited number of such training systems. Furthermore, certain weldingsystems may not adequately train welding operators to perform highquality welds.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a welding system inaccordance with aspects of the present disclosure;

FIG. 2 is a block diagram of an embodiment of portions of the weldingsystem of FIG. 1 in accordance with aspects of the present disclosure;

FIG. 2A is a schematic diagram of an embodiment of circuitry of thewelding torch of FIG. 1 in accordance with aspects of the presentdisclosure;

FIG. 3 is a perspective view of an embodiment of the welding torch ofFIG. 1 in accordance with aspects of the present disclosure;

FIG. 4 is a perspective view of an embodiment of the welding stand ofFIG. 1 in accordance with aspects of the present disclosure;

FIG. 5 is a perspective view of an embodiment of a calibration device inaccordance with aspects of the present disclosure;

FIG. 6 is a perspective view of an embodiment of a fixture assembly inaccordance with aspects of the present disclosure;

FIG. 7 is a perspective view of a welding wire stickout calibration toolin accordance with aspects of the present disclosure;

FIG. 8 is a top view of the welding wire stickout calibration tool ofFIG. 7 in accordance with aspects of the present disclosure;

FIG. 9 is an embodiment of a method for calibrating wire stickout from awelding torch in accordance with aspects of the present disclosure;

FIG. 10 is a perspective view of an embodiment of a welding consumablehaving physical marks in accordance with aspects of the presentdisclosure;

FIG. 11 is a perspective view of an embodiment of welding wire havingphysical marks in accordance with aspects of the present disclosure;

FIG. 12 is a perspective view of an embodiment of a vertical armassembly of the welding stand of FIG. 1 in accordance with aspects ofthe present disclosure;

FIG. 13 is a perspective view of an embodiment of an overhead weldingarm assembly in accordance with aspects of the present disclosure;

FIG. 14 is a block diagram of an embodiment of welding software havingmultiple training modes in accordance with aspects of the presentdisclosure;

FIG. 15 is a block diagram of an embodiment of a virtually reality modeof welding software in accordance with aspects of the presentdisclosure;

FIG. 16 is an embodiment of a method for integrating training resultsdata in accordance with aspects of the present disclosure;

FIG. 17 is an embodiment of a chart illustrating multiple sets ofwelding data for a welding operator in accordance with aspects of thepresent disclosure;

FIG. 18 is an embodiment of a chart illustrating welding data for awelder compared to welding data for a class in accordance with aspectsof the present disclosure;

FIG. 19 is a block diagram of an embodiment of a data storage system(e.g., cloud storage system) for storing certification status data inaccordance with aspects of the present disclosure;

FIG. 20 is an embodiment of a screen illustrating data corresponding toa weld in accordance with aspects of the present disclosure;

FIG. 21 is an embodiment of a screen illustrating a discontinuityanalysis of a weld in accordance with aspects of the present disclosure;

FIG. 22 is a block diagram of an embodiment of a welding instructorscreen of welding software in accordance with aspects of the presentdisclosure;

FIG. 23 is an embodiment of a method for weld training using augmentedreality in accordance with aspects of the present disclosure;

FIG. 24 is an embodiment of another method for weld training usingaugmented reality in accordance with aspects of the present disclosure;

FIG. 25 is a block diagram of an embodiment of a welding torch inaccordance with aspects of the present disclosure;

FIG. 26 is an embodiment of a method for providing vibration feedback toa welding operator using a welding torch in accordance with aspects ofthe present disclosure;

FIG. 27 is a graph of an embodiment of two patterns each including adifferent frequency for providing vibration feedback to a weldingoperator in accordance with aspects of the present disclosure;

FIG. 28 is a graph of an embodiment of two patterns each including adifferent modulation for providing vibration feedback to a weldingoperator in accordance with aspects of the present disclosure;

FIG. 29 is a graph of an embodiment of two patterns each including adifferent amplitude for providing vibration feedback to a weldingoperator in accordance with aspects of the present disclosure;

FIG. 30 is a perspective view of an embodiment of a welding torch havingspherical markers that may be used for tracking the welding torch inaccordance with aspects of the present disclosure;

FIG. 31 is perspective view of an embodiment of the welding torch, takenalong line 31-31 of FIG. 30 in accordance with aspects of the presentdisclosure;

FIG. 32 is a top view of an embodiment of the welding torch and visualmarkers in accordance with aspects of the present disclosure;

FIG. 33 is an embodiment of a method for displaying on a display of awelding torch a welding parameter in relation to a threshold inaccordance with aspects of the present disclosure;

FIG. 34 is an embodiment of a set of screenshots of a display of awelding torch for showing a welding parameter in relation to a thresholdin accordance with aspects of the present disclosure;

FIG. 35 is an embodiment of a method for tracking a welding torch in awelding system using at least four markers in accordance with aspects ofthe present disclosure;

FIG. 36 is an embodiment of a method for detecting the ability for aprocessor to communicate with a welding torch in accordance with aspectsof the present disclosure;

FIG. 37 is an embodiment of a method for calibrating a curved weld jointthat may be used with a welding system in accordance with aspects of thepresent disclosure;

FIG. 38 is a diagram of an embodiment of a curved weld joint inaccordance with aspects of the present disclosure;

FIG. 39 is a diagram of an embodiment of a curved weld joint and amarking tool in accordance with aspects of the present disclosure;

FIG. 40 is an embodiment of a method for tracking a multi-pass weldingoperation in accordance with aspects of the present disclosure;

FIG. 41 is a perspective view of an embodiment of a welding stand inaccordance with aspects of the present disclosure;

FIG. 42 is a cross-sectional view of an embodiment of a welding surfaceof the welding stand of FIG. 41 in accordance with aspects of thepresent disclosure;

FIG. 43 is a cross-sectional view of an embodiment of a sensing devicehaving a removable cover in accordance with aspects of the presentdisclosure;

FIG. 44 is a perspective view of an embodiment of a calibration tool inaccordance with aspects of the present disclosure;

FIG. 45 is a perspective view of the calibration tool of FIG. 44 havingan outer cover removed in accordance with aspects of the presentdisclosure;

FIG. 46 is a side view of an embodiment of a pointed tip of acalibration tool in accordance with aspects of the present disclosure;

FIG. 47 is a side view of an embodiment of a rounded tip of acalibration tool in accordance with aspects of the present disclosure;

FIG. 48 is a side view of an embodiment of a rounded tip of acalibration tool having a small pointed tip in accordance with aspectsof the present disclosure;

FIG. 49 is an embodiment of a method for detecting a calibration pointin accordance with aspects of the present disclosure;

FIG. 50 is an embodiment of a method for determining a welding scorebased on a welding path in accordance with aspects of the presentdisclosure;

FIG. 51 is an embodiment of a method for transitioning between weldingmodes using a user interface of a welding torch in accordance withaspects of the present disclosure;

FIG. 52 is an embodiment of a remote welding training system inaccordance with aspects of the present disclosure;

FIG. 53 is an embodiment of a dashboard page with welding data fromdifferent operators, in accordance with aspects of the presentdisclosure;

FIG. 54 is an embodiment of a welding system with depth sensors and alocal positioning system, in accordance with aspects of the presentdisclosure;

FIG. 55 is an embodiment of a method of controlling visual markers ofthe welding torch to track the movement and position of the weldingtorch, in accordance with aspects of the present disclosure;

FIG. 56 is a cross-sectional view of a base component with visualmarkers, in accordance with aspects of the present disclosure;

FIG. 57 is a perspective view of an embodiment of the arms and clampassembly of the welding stand, in accordance with aspects of the presentdisclosure;

FIG. 58 is a top view of an embodiment of a mount of the clamp assemblyof FIG. 57, taken along line 58-58, in accordance with aspects of thepresent disclosure;

FIG. 59 is perspective view of an embodiment of a calibration blockcoupled to the clamp assembly of FIG. 57, in accordance with aspects ofthe present disclosure;

FIG. 60 is an embodiment of a method for the set up of the arms of thetraining stand for an out of position welding assignment, in accordancewith aspects of the present disclosure;

FIG. 61 is an embodiment of a method for the selection and execution ofa multi-pass welding assignment with the welding system, in accordancewith aspects of the present disclosure;

FIG. 62 is an embodiment of a screen illustrating data, including arcparameters, corresponding to a weld in accordance with aspects of thepresent disclosure;

FIG. 63 is an embodiment of a screen illustrating data corresponding toa weld test for which an arc has not been detected in accordance withaspects of the present disclosure;

FIG. 64 is an embodiment of a screen illustrating assignment developmentroutines in accordance with aspects of the present disclosure;

FIG. 65 is an embodiment of a screen illustrating properties relating toa welding procedure in accordance with aspects of the presentdisclosure;

FIG. 66 is an embodiment of a screen illustrating data corresponding toa simulated weld in accordance with aspects of the present disclosure;

FIG. 67 is an embodiment of a screen illustrating data corresponding toa weld prior to initiation of the weld in accordance with aspects of thepresent disclosure;

FIG. 68 is an embodiment of a screen illustrating a summary of weld testparameters in accordance with aspects of the present disclosure;

FIG. 69 is an embodiment of a screen illustrating data, including arcparameters, corresponding to a weld during a weld test in accordancewith aspects of the present disclosure;

FIG. 70 is an embodiment of a screen illustrating data, including heatinput, corresponding to a weld in accordance with aspects of the presentdisclosure;

FIG. 71 is a diagram of an embodiment of the aim of a welding torchrelative to a workpiece in accordance with aspects of this presentdisclosure;

FIG. 72 is an embodiment of a marker that may be applied to theworkpiece by a marking tool in accordance with aspects of this presentdisclosure;

FIG. 73 is an embodiment of a marker that may be applied to theworkpiece by a marking tool in accordance with aspects of this presentdisclosure;

FIG. 74 is an embodiment of a marker that may be applied to theworkpiece by a marking tool in accordance with aspects of this presentdisclosure;

FIG. 75 is an embodiment of a marker that may be applied to theworkpiece by a marking tool in accordance with aspects of this presentdisclosure;

FIG. 76 is a perspective view of an embodiment of a welding system witha marking tool and markers applied to surfaces of a workpiece with themarking tool in accordance with aspects of this present disclosure; and

FIG. 77 is an embodiment of a method of calibrating sets of visualmarkers of the welding torch, in accordance with aspects of the presentdisclosure.

DETAILED DESCRIPTION

FIG. 1 is a block diagram of an embodiment of one or more weldingsystems 10. As used herein, a welding system may include any suitablewelding related system, including, but not limited to, a weldingtraining system, a live welding system, a remote welding training system(e.g., helmet training system), a simulated welding system, a virtualreality welding system, and so forth. For example, the welding system 10may include, but is not limited to, a LiveArc™ Welding PerformanceManagement System available from Miller Electric of Appleton, Wis. Thewelding system 10 may include a welding stand 12 for providing supportfor various training devices. For example, the stand 12 may beconfigured to support a welding surface, a workpiece 82, a fixture, oneor more training arms, and so forth. The welding system 10 includes awelding torch 14 that may be used by a welding operator (e.g., weldingstudent) to perform welding operations (e.g., training operations). Asdescribed in greater detail below, the welding torch 14 may beconfigured with a user interface configured to receive inputs from thewelding operator, control circuitry configured to process the inputs,and a communication interface configured to provide the inputs toanother device. Furthermore, the welding torch 14 may include one ormore display and/or indicators to provide data to the welding operator.

Moreover, the welding system 10 includes one or more sensing devices 16(e.g., sensor, sensing assembly, and so forth) used to sense a positionof one or more welding devices and/or to sense an orientation of one ormore welding devices. For example, the sensing device 16 may be used tosense a position and/or an orientation of the stand 12, the weldingtorch 14, a welding surface, the workpiece 82, a fixture, one or moretraining arms, the operator, an identification token, and so forth. Theone or more sensing devices 16 may include any suitable sensing device,such as an inertial sensing device or a motion tracking device.Furthermore, the sensing device 16 may include one or more cameras, suchas one or more infrared cameras, one or more visible spectrum cameras,one or more high dynamic range (HDR) cameras, and so forth.Additionally, or in the alternative, the sensing device 16 may includeone or more depth sensors to determine relative distances between therespective depth sensors 16 and an object (e.g., welding torch 14,workpiece 82, operator, and so forth). The sensing devices 16 may bepositioned in various locations about the welding environment of thetraining system 10, thereby enabling some sensing devices 16 to monitorthe welding environment (e.g., track movement of an object) when othersensing devices 16 are obscured. For example, a sensing device 16 (e.g.,camera, depth sensor) integrated with a welding helmet 41 may facilitatetracking the position, orientation, and/or movement of the welding torch14 relative to the workpiece 82 when the welding torch 14 is at leastpartially obscured from other sensing devices 16 by the workpiece 82 orthe operator. For example, markers disposed on the welding torch 14 thatfacilitate tracking the welding torch 14 may be partially obscured froma first sensing device 16, yet be observable by another sensing device16 of the helmet 41. The other sensing device 16 of the helmet 41 may beindependent of the first sensing device 16. Furthermore, a sensingdevice 16 (e.g., accelerometer) integrated with the welding torch 14 mayfacilitate tracking the position, orientation, and/or movement of thewelding torch 14 relative to the workpiece 82 when the welding torch 14is at least partially obscured from other sensing devices 16 (e.g.,cameras, depth sensors) by the workpiece 82 or the operator.

The sensing device 16 is communicatively coupled to a computer 18. Thesensing device 16 is configured to provide data (e.g., image data,acoustic data, sensed data, six degrees of freedom (6DOF) data, etc.) tothe computer 18. Furthermore, the sensing device 16 may be configured toreceive data (e.g., configuration data, setup data, commands, registersettings, etc.) from the computer 18. The computer 18 includes one ormore processors 20, memory devices 22, and storage devices 24. Thecomputer 18 may include, but is not limited to, a desktop, a laptop, atablet, a mobile device, a wearable computer, or any combinationthereof. The processor(s) 20 may be used to execute software, such aswelding software, image processing software, sensing device software,and so forth. Moreover, the processor(s) 20 may include one or moremicroprocessors, such as one or more “general-purpose” microprocessors,one or more special-purpose microprocessors and/or application specificintegrated circuits (ASICS), or some combination thereof. For example,the processor(s) 20 may include one or more reduced instruction set(RISC) processors.

The storage device(s) 24 (e.g., nonvolatile storage) may include ROM,flash memory, a hard drive, or any other suitable optical, magnetic, orsolid-state storage medium, or a combination thereof. The storagedevice(s) 24 may store data (e.g., data corresponding to a weldingoperation, video and/or parameter data corresponding to a weldingoperation, data corresponding to an identity and/or a registrationnumber of the operator, data corresponding to past operator performance,etc.), instructions (e.g., software or firmware for the welding system,the sensing device 16, etc.), and any other suitable data. As will beappreciated, data that corresponds to a welding operation may include avideo recording of the welding operation, a simulated video, anorientation of the welding torch 14, a position of the welding torch 14,a work angle, a travel angle, a distance between a contact tip of thewelding torch 14 and a workpiece, a travel speed, an aim, a voltage, acurrent, a traversed path, a discontinuity analysis, welding devicesettings, and so forth.

The memory device(s) 22 may include a volatile memory, such as randomaccess memory (RAM), and/or a nonvolatile memory, such as read-onlymemory (ROM). The memory device(s) 22 may store a variety of informationand may be used for various purposes. For example, the memory device(s)22 may store processor-executable instructions (e.g., firmware orsoftware) for the processor(s) 20 to execute, such as instructions for awelding training simulation, for the sensing device 16, and/or for anoperator identification system 43. In addition, a variety of controlregimes for various welding processes, along with associated settingsand parameters may be stored in the storage device(s) 24 and/or memorydevice(s) 22, along with code configured to provide a specific output(e.g., initiate wire feed, enable gas flow, capture welding currentdata, detect short circuit parameters, determine amount of spatter,etc.) during operation. The welding power supply 28 may be used toprovide welding power to a live-arc welding operation, and the wirefeeder 30 may be used to provide welding wire to the live-arc weldingoperation.

The welding system 10 includes a display 32 for displaying data and/orscreens associated with welding (e.g., to display data corresponding toa welding software). For example, the display 32 may provide a graphicaluser interface to a welding operator (e.g., welding instructor, weldingstudent). The graphical user interface may provide various screens toenable the welding instructor to organize a class, provide assignmentsto the class, analyze assignments performed by the class, provideassignments to an individual, analyze assignments performed by theindividual, add, change, and/or delete parameters for a weldingassignment, and so forth. Furthermore, the graphical user interface mayprovide various screens to enable a welding operator (e.g., weldingstudent) to perform a welding assignment, view results from priorwelding assignments, and so forth. In certain embodiments, the display32 may be a touch screen display configured to receive touch inputs, andto provide data corresponding to the touch inputs to the computer 18.

An external display 34 is coupled to the computer 18 to enable anindividual located remotely from the welding system 10 to view datacorresponding to the welding system 10. Furthermore, a network device 36is coupled to the computer 18 to enable the computer 18 to communicatewith other devices connected to the Internet or another network 38(e.g., for providing test results to another device and/or for receivingtest results from another device). For example, the network device 36may enable the computer 18 to communicate with an external weldingsystem 40, a production welding system 42, a remote computer 44, and/ora data storage system (e.g., cloud storage system) 318. As may beappreciated, the welding system 10 described herein may be used to trainwelding students in a cost effective manner. In some embodiments, theone or more welding systems 10 may include a helmet 41 having a display32 and one or more sensing devices 16, such as optical or acousticsensing devices. As described in detail below, the helmet 41 iscommunicatively coupled to the computer 18, and the helmet 41 mayfacilitate welding training and/or welding monitoring without thetraining stand 12. In some embodiments, the one or more sensing devices16 integrated with the helmet 41 may facilitate welding training and/orwelding monitoring without separate sensing devices 16 external to thehelmet 41. Furthermore, the welding system 10 is configured to integratereal welding with simulated welding in a manner that prepares weldingstudents for high quality production welding.

An operator identification system 43 is coupled to the computer 18 toenable an operator utilizing the welding system 10 to be identified. Theoperator identification system 43 utilizes one or more types of operatorinformation (e.g., identifiers) to identify the operator. Operatorinformation may include, but is not limited to, a resettable identifier45 (e.g., password, motion sequence, operator-performed action), abiometric identifier 47 (e.g., retinal scan, fingerprint, palm print,facial profile, voice profile, inherent operator trait), informationbased at least in part on a biometric identifier 47, a token 49 (e.g.,key, key fob, radio frequency identification (RFID) tag, passcard,barcode, physical identifier), or any combination thereof. Additionally,or in the alternative, an instructor or manager may provide an input tothe operator identification system 43 to verify the identity of theoperator, thereby authorizing the operator for the welding session(e.g., welding assignment) and the associated weld data. That is, theidentification of an operator may involve one or more steps, such asoperator identification via information received from the operator, andoperator verification via information received from the instructorand/or manager of the operator. In some embodiments, the operatoridentification system 43 may utilize the one or more sensing devices 16to facilitate operator identification. For example, a camera ormicrophone of the welding system 10 may receive the biometric identifier47. Moreover, the operator identification system 43 may have an inputdevice 51 (e.g., keypad, touch screen, retinal scanner, fingerprintsensor, camera, microphone, barcode scanner, radio transceiver, and soforth) configured to receive the one or more types of operatoridentification information.

The operator identification system 43 may identify the operator prior toperforming a weld process (e.g., live process, training process,simulated process, virtual reality process) or after performing the weldprocess. In some embodiments, the operator identification system 43 mayenable or lock out an operator from utilizing the welding system 10based on the one or more identifiers received at the input device 51.For example, the operator identification system 43 may lock out a firstoperator (e.g., student) from utilizing the welding system 10 until theoperator identification system 43 receives a first input from the firstoperator that may identify the first operator. In some embodiments, thewelding system 10 may enable the first operator to perform a weldingsession with the welding system 10 without verification of the identityof the first operator; however, the welding system 10 may store and/ortransmit the welding data associated with such a welding session onlyupon verification of the identity of the first operator based at leastin part on a second input from a second operator (e.g., instructor,administrator). That is, the operator identification system 43 maydisable the storage or transmission of the welding data associated witha welding session until the identity of the first operator thatperformed the welding session is verified by the second operator.Moreover, some embodiments of the welding system 10 may lock out thefirst operator from utilizing the welding system until a second input isreceived from the second operator that verifies the identity of thefirst operator, which was preliminarily determined based on the firstinput from the first operator. In some embodiments, the operatoridentification system 43 may identify the operator during a weldprocess, such as via an identifying characteristic of an operator duringthe weld process. For example, a first operator may hold the weldingtorch differently than a second operator, and a sensing device 16 (e.g.,camera) coupled to the operator identification system 43 may facilitatedistinguishing the first operator from the second operator.Additionally, or in the alternative, the operator identification system43 may include a sensor (e.g., fingerprint scanner, camera, microphone)on the welding torch 14 or the helmet 41. In some embodiments, aninstructor and/or a manager may confirm upon completion of a weldprocess that the identified operator performed the weld process.

The operator identification system 43 may communicate with the computer18 to determine the identity of the operator utilizing the receivedidentification information. In some embodiments, the computer 18 maycommunicate with the network 38 and/or a remote computer 44 to determinethe identity of the operator. The computer 18 may control the display 32to display at least some of the information associated with the operatorupon identification of the operator. For example, the display 32 maypresent the name, a photo, registration number, experience level, or anycombination thereof. In some embodiments, the operator identificationsystem 43 may be utilized with one or more welding systems 10.

The computer 18 may receive welding data (e.g., welding parameters, arcparameters) corresponding to a welding session (e.g., weldingassignment) during and/or after the respective welding session isperformed by the operator. The computer 18 may receive the welding datafrom the network 38, one or more sensing devices 16, the welding torch14, the welding power supply 28, the wire feeder 30, or the helmet 41,or any combination thereof. Additionally, or in the alternative, thecomputer 18 may associate the received welding data with the identity ofthe operator, such as via a registration number unique to the operator,the operator's name, and/or a photograph of the operator. Moreover, thecomputer 18 may transmit the associated welding data and identity of theoperator (e.g., registration number) to a data storage system within thewelding system 10 or located remotely via the network 38. Association ofthe welding data with the identity of the operator (e.g., via theregistration number) enables significantly more than the collection ofunassociated welding data from operators. That is, association of thewelding data with a registration number unique to the operator enablessomeone (e.g., the operator, instructor, manager) that is either localor remote from the operator to track the performance, progress, andskills of the operator over time via the registration number.

FIG. 2 is a block diagram of an embodiment of portions of the weldingsystem 10 of FIG. 1. As illustrated, a power distribution assembly 46provides power to the welding torch 14 and the computer 18. Moreover,the welding torch 14 includes control circuitry 52 configured to controlthe operation of the welding torch 14. In the illustrated embodiment,the control circuitry 52 includes one or more processors 54, memorydevices 56, and storage devices 58. In other embodiments, the controlcircuitry 52 may not include the processors 54, the memory devices 56,and/or the storage devices 58. The processor(s) 54 may be used toexecute software, such as welding torch software. Moreover, theprocessor(s) 54 may be similar to the processor(s) 20 describedpreviously. Furthermore, the memory device(s) 56 may be similar to thememory device(s) 22, and the storage device(s) 58 may be similar to thestorage device(s) 24.

The welding torch 14 includes a user interface 60 to enable a weldingoperator (e.g., welding student, welding instructor, etc.) to interactwith the welding torch 14 and/or to provide inputs to the welding torch14. For example, the user interface 60 may include buttons, switches,touch screens, touchpads, scanners, and so forth. The inputs provided tothe welding torch 14 by the welding operator may be provided to thecomputer 18. For example, the inputs provided to the welding torch 14may be used to control welding software being executed by the computer18. As such, the welding operator may use the user interface 60 on thewelding torch 14 to navigate the welding software screens, setupprocedures, data analysis, welding courses, make selections within thewelding software, configure the welding software, and so forth. Thus,the welding operator can use the welding torch 14 to control the weldingsoftware (e.g., the welding operator does not have to put down thewelding torch 14 to use a different input device). The welding torch 14also includes visual indicators 61, such as a display 62 and LEDs 64.The visual indicators 61 may be configured to indicate or display dataand/or images corresponding to a weld, welding training, and/or weldingsoftware. For example, the visual indicators 61 may be configured toindicate a welding torch orientation, a welding torch travel speed, awelding torch position, a contact tip to workpiece distance, an aim ofthe welding torch 14, training information for the welding operator, andso forth. Moreover, the visual indicators 61 may be configured toprovide visual indications before a weld, during a weld, and/or after aweld. In certain embodiments, the LEDs 64 may illuminate to facilitatetheir detection by the sensing device 16. In such embodiments, the LEDs64 may be positioned to enable the sensing device 16 to determine aposition and/or an orientation of the welding torch 14 based on aspatial position of the LEDs 64. Each LED 64 may emit light in thevisible, infrared, or ultraviolet spectrum, or a combination thereof.

As may be appreciated, FIG. 71 illustrates an embodiment of the aim ofthe welding torch 14. Where a wire electrode 174 extends along an axis53 of the torch 14, a projected line 55 along the axis 53 extending fromthe wire electrode intersects the workpiece 82 at an intersection point57. As utilized herein, the term “aim” may be defined as the shortestdistance 59 along the workpiece 82 between the intersection point 57 anda center 63 of a joint 67 of the workpiece 82.

Returning to FIG. 2, in certain embodiments, the welding torch 14includes power conversion circuitry 66 configured to receive power fromthe power distribution assembly 46, the computer 18, or another device,and to convert the received power for powering the welding torch 14. Incertain embodiments, the welding torch 14 may receive power that isalready converted and/or does not utilize power conversion. Moreover, insome embodiments, the welding torch 14 may be powered by a battery orany suitable powering mechanism. The welding torch 14 also includes acommunication interface 68 (e.g., RS-232 driver) to facilitatecommunication between the welding torch 14 and the computer 18.Accordingly, inputs provided to the welding torch 14 may be provided tothe computer 18.

The welding torch 14 includes a trigger 70 configured to mechanicallyactuate a trigger switch 72 between an open position (as illustrated)and a closed position. The trigger 70 provides a conductor 71 to carry asignal to the control circuitry 52 to indicate whether the triggerswitch 72 is in the open position or the closed position. The wirefeeder 30, the welding power supply 28, and/or the computer 18 maydetermine whether there is continuity through the welding torch 14across a first trigger conductor 74 and a second trigger conductor 76.The trigger switch 72 is electrically coupled between the first triggerconductor 74 and the second trigger conductor 76. Continuity across thefirst trigger conductor 74 and the second trigger conductor 76 may bedetermined by applying a voltage across the conductors 74 and 76,applying a current across the conductors 74 and 76, measuring aresistance across the conductors 74 and 76, and so forth. In certainembodiments, portions of the first trigger conductor 74 and/or portionsof the second trigger conductor 76 may be disposed within a connector ofthe welding torch 14. Furthermore, in certain embodiments, thearrangement of switches and/or conductors within the welding torch 14may be different than illustrated in FIG. 2.

The welding power supply 28 may determine whether to enable weldingpower to flow through the welding torch 14 based on whether there iscontinuity across the conductors 74 and 76. For example, the weldingpower supply 28 may enable welding power to flow through the weldingtorch 14 while there is continuity across the conductors 74 and 76, andthe welding power supply 28 may block welding power from flowing throughthe welding torch 14 while there is an open circuit across theconductors 74 and 76. Furthermore, the wire feeder 30 may providewelding wire to the welding torch 14 while there is continuity acrossthe conductors 74 and 76, and may block welding wire from being providedto the welding torch 14 while there is an open circuit across theconductors 74 and 76. Moreover, the computer 18 may use the continuityacross the conductors 74 and 76 and/or the position of the trigger 70 ortrigger switch 72 to start and/or stop a welding operation, a weldingsimulation, data recording, and so forth.

With the trigger switch 72 in the open position, there is an opencircuit across the conductors 74 and 76, thus, the open position of thetrigger switch 72 blocks electron flow between the conductors 74 and 76.Accordingly, the welding power supply 28 may block welding power fromflowing through the welding torch 14 and the wire feeder 30 may blockwelding wire from being provided to the welding torch 14. Pressing thetrigger 70 directs the trigger switch 72 to the closed position wherethe trigger switch 72 remains as long as the trigger 70 is pressed. Withthe trigger switch 72 in the closed position, there is continuitybetween the first trigger conductor 74 and a conductor 77 electricallyconnected to the trigger switch 72 and a training switch 78.

The training switch 78 is electrically coupled between the first triggerconductor 74 and the second trigger conductor 76. Moreover, the trainingswitch 78 is electrically controlled by the control circuitry 52 to anopen position or to a closed position. In certain embodiments, thetraining switch 78 may be any suitable electrically controlled switch,such as a transistor, relay, etc. The control circuitry 52 mayselectively control the training switch 78 to the open position or tothe closed position. For example, while welding software of the weldingsystem 10 is operating in a live-arc mode, the control circuitry 52 maybe configured to control the training switch 78 to the closed positionto enable a live welding arc while the trigger 70 is pressed. Incontrast, while welding software of the welding system 10 is operatingin any mode other than the live-arc mode (e.g., simulation, virtualreality, augmented reality, etc.), the control circuitry 52 may beconfigured to control the training switch 78 to the open position toblock a live welding arc (by blocking electron flow between theconductors 74 and 76).

In certain embodiments, the training switch 78 may default to the openposition, thereby establishing an open circuit across the conductors 74and 76. As may be appreciated, while the training switch 78 is in theopen position, there will be an open circuit across the conductors 74and 76 regardless of the position of the trigger switch 72 (e.g.,electron flow between the conductors 74 and 76 is blocked by the openposition of the training switch 78). However, while the training switch78 is controlled to the closed position, and the trigger switch 72 is inthe closed position, conductivity is established between the conductors74 and 76 (e.g., electron flow between the conductors 74 and 76 isenabled). Accordingly, the welding power supply 28 may enable weldingpower to flow through the welding torch 14 only while the trainingswitch 78 is in the closed position and while the trigger switch 72 isin the closed position. For example, welding power may flow from thewelding power supply 28, through a weld cable 80, the welding torch 14,a workpiece 82, and return to the welding power supply 28 via a workcable 84 (e.g., electrode-negative, or straight polarity). Conversely,welding power may flow from the welding power supply 28, through thework cable 84, the workpiece 82, the welding torch 14, and return to thewelding power supply 28 via the weld cable 80 (e.g., electrode-positive,or reverse polarity).

As may be appreciated, the training switch 78 may be physically locatedin any suitable portion of the welding system 10, such as the computer18, and so forth. Furthermore, in certain embodiments, the functionalityof the training switch 78 may be replaced by any suitable hardwareand/or software in the welding system 10.

FIG. 2A is a schematic diagram of an embodiment of circuitry of thewelding torch 14 of FIG. 1. In the illustrated embodiment, the triggerswitch 72 selectively connects a power supplying conductor (e.g.,voltage source, etc.) to the conductor 71. Accordingly, while thetrigger switch 72 is open, no voltage is applied to the conductor 71,and while the trigger switch 72 is closed, voltage from the powersupplying conductor is supplied to the conductor 71. A trigger enablesignal (e.g., TRIGGER_EN) may be provided by the control circuitry 52 toselectively control the training switch 78, and thereby control a feederenable switch 85. For example, when the trigger enable signal controlsthe training switch 78 to an open position, no voltage is applied to thefeeder enable switch 85 (e.g., via the FEEDER_EN connection), therebymaintaining the feeder enable switch 85 in the open position.Conversely, when the trigger enable signal controls the training switch78 to a closed position, voltage is applied to the feeder enable switch85, thereby controlling the feeder enable switch 85 to the closedposition. With the feeder enable switch 85 in the closed position,conductivity between the conductors 74 and 76 is established. While oneexample of welding torch 14 circuitry is provided, any suitablecircuitry may be used within the welding torch 14. A microprocessor ofthe control circuitry 52 may pulse the trigger enable signal atpredetermined intervals to provide an indication to detection circuitryof the control circuitry 52 that the trigger enable signal is workingproperly. If the detection circuitry does not detect the trigger enablesignal, the trigger may not be enabled.

FIG. 3 is a perspective view of an embodiment of the welding torch 14 ofFIGS. 1 and 2. As illustrated, the user interface 60 includes multiplebuttons 86 which may be used to provide inputs to the welding torch 14.For example, the buttons 86 may enable a welding operator to navigatethrough welding software. Furthermore, the welding torch 14 includes thedisplay 62 which may show the welding operator data corresponding to thewelding software, data corresponding to a welding operation, and soforth. As illustrated, the LEDs 64 may be positioned at variouslocations on the welding torch 14. Accordingly, the LEDs 64 may beilluminated to facilitate detection by the sensing device 16. Asdiscussed in detail below, one or more sets of LEDs 64 may be arrangedon the welding torch 14 to facilitate detection by the sensing device 16regardless of the position of the welding torch in the weldingenvironment. For example, one or more sets of LEDs 64 may be arrangedabout the welding torch 14 and oriented (e.g., centered) in directionsthat enable the sensing device 16 to detect the position and orientationof the welding torch 14 in a flat welding position, a horizontal weldingposition, a vertical welding position, and an overhead position.Moreover, the one or more sets of LEDs 64 may enable the sensing device16 to substantially continuously detect the movement of the weldingtorch 14 between various welding positions in the welding environmentprior to initiating a welding process, movement of the welding torchduring a welding process, and movement of the welding torch aftercompleting a welding process, or any combination thereof. In someembodiments, a scanning device 65, such as a finger print scanner, maybe arranged on the welding torch 14. The scanning device 65 may be apart of the operator identification system 43. The operator may utilizethe scanning device 65 to provide identification information to theoperator identification system 43 of the welding system 10. For example,the operator may scan a finger before and/or after performing a weldprocess to facilitate verification that the identified operatorperformed the weld process. In some embodiments, the operator mayutilize the scanning device 65 within a relatively brief window (e.g.,approximately 3, 5, 10, or 15 seconds) of initiating or completing aweld process to verify the identity of the operator. That is, thewelding system 10 and/or the welding torch 14 may lock out the operatorfrom initiating or completing a weld process if the weld process is notinitiated within the brief window after verification of the identity ofthe operator. Accordingly, the operator identification system 43 may beutilized to reduce or eliminate instances in which the performance of agiven weld process by a second operator and the associated weld datafrom the given weld process is erroneously attributed to a firstoperator that did not perform the given weld process.

FIG. 4 is a perspective view of an embodiment of the stand 12 of FIG. 1.The stand 12 includes a welding surface 88 on which live welds (e.g.,real welds, actual welds) and/or simulated welds may be performed. Legs90 provide support to the welding surface 88. In certain embodiments,the welding surface 88 may include slots 91 to aid a welding operator inpositioning and orienting the workpiece 82. In certain embodiments, theposition and orientation of the workpiece 82 may be provided to weldingsoftware of the welding system 10 to calibrate the welding system 10.For example, a welding operator may provide an indication to the weldingsoftware identifying which slot 91 of the welding surface 88 theworkpiece 82 is aligned with. Furthermore, a predefined weldingassignment may direct the welding operator to align the workpiece 82with a particular slot 91. In certain embodiments, the workpiece 82 mayinclude an extension 92 configured to extend into one or more of theslots 91 for alignment of the workpiece 82 with the one or more slots91. As may be appreciated, each of the slots 91 may be positioned at alocation corresponding to a respective location defined in the weldingsoftware.

The welding surface 88 includes a first aperture 93 and a secondaperture 94. The first and second apertures 93 and 94 may be usedtogether to determine a position and/or an orientation of the weldingsurface 88. As may be appreciated, in certain embodiments at least threeapertures may be used to determine the position and/or the orientationof the welding surface 88. In some embodiments, more than threeapertures may be used to determine the position and/or the orientationof the welding surface 88. The first and second apertures 93 and 94 maybe positioned at any suitable location on the welding surface 88, andmay be any suitable size. In certain embodiments, the position and/ororientation of the welding surface 88 relative to the sensing device 16may be calibrated using the first and second apertures 93 and 94. Forexample, as described in greater detail below, a calibration deviceconfigured to be sensed by the sensing device 16 may be inserted intothe first aperture 93, or touched to the first aperture 93. While thecalibration device is inserted into, or touching, the first aperture 93,a user input provided to the welding software (or other calibrationsoftware) may indicate that the calibration device is inserted into thefirst aperture 93. As a result, the welding software may establish acorrelation between a first data set (e.g., calibration data) receivedfrom the sensing device 16 (e.g., position and/or orientation data) at afirst time and the location of first aperture 93. The calibration devicemay next be inserted into the second aperture 94, or touched to thesecond aperture 94. While the calibration device is inserted into, ortouching, the second aperture 94, a user input provided to the weldingsoftware may indicate that the calibration device is inserted into thesecond aperture 94. As a result, the welding software may establish acorrelation between a second data set (e.g., calibration data) receivedfrom the sensing device 16 at a second time and the location of secondaperture 94. Thus, the welding software may be able to calibrate theposition and/or orientation of the welding surface 88 relative to thesensing device 16 using the first data set received at the first timeand the second data set received at the second time.

The welding surface 88 also includes a first marker 95 and a secondmarker 96. The first and second markers 95 and 96 may be used togetherto determine a position and/or an orientation of the welding surface 88.As may be appreciated, in certain embodiments at least three markers maybe used to determine the position and/or the orientation of the weldingsurface 88. In some embodiments, more than three markers may be used todetermine the position and/or the orientation of the welding surface 88.The first and second markers 95 and 96 may be formed from any suitablematerial. Moreover, in certain embodiments, the first and second markers95 and 96 may be built into the welding surface 88, while in otherembodiments, the first and second markers 95 and 96 may be attached tothe welding surface 88. For example, the first and second markers 95 and96 may be attached to the welding surface 88 using an adhesive and/orthe first and second markers 95 and 96 may be stickers (e.g., tape). Thefirst and second markers 95 and 96 may have any suitable shape, size,and/or color. Furthermore, in certain embodiments, the first and secondmarkers 95 and 96 may be a reflector (e.g., retroreflector) formed froma reflective material. The first and second markers 95 and 96 may beused by the welding system 10 to calibrate the position and/ororientation of the welding surface 88 relative to the sensing device 16without a separate calibration device. Accordingly, the first and secondmarkers 95 and 96 are configured to be detected by the sensing device16. In certain embodiments, the first and second markers 95 and 96 maybe positioned at predetermined locations on the welding surface 88.Furthermore, the welding software may be programmed to use thepredetermined locations to determine the position and/or the orientationof the welding surface 88. In other embodiments, the location of thefirst and second markers 95 and 96 may be provided to the weldingsoftware during calibration. With the first and second markers 95 and 96on the welding surface 88, the sensing device 16 may sense the positionand/or orientation of the first and second markers 95 and 96 relative tothe sensing device 16. Using this sensed data in conjunction with thelocation of the first and second markers 95 and 96 on the weldingsurface 88, the welding software may be able to calibrate the positionand/or orientation of the welding surface 88 relative to the sensingdevice 16. In some embodiments, the welding surface 88 may be removableand/or reversible. In such embodiments, the welding surface 88 may beflipped over, such as if the welding surface 88 become worn.

In the illustrated embodiment, the workpiece 82 includes a first marker98 and a second marker 99. The first and second markers 98 and 99 may beused together to determine a position and/or an orientation of theworkpiece 82. As may be appreciated, at least two markers are used todetermine the position and/or the orientation of the workpiece 82. Incertain embodiments, more than two markers may be used to determine theposition and/or the orientation of the workpiece 82. The first andsecond markers 98 and 99 may be formed from any suitable material.Moreover, in certain embodiments, the first and second markers 98 and 99may be built into the workpiece 82, while in other embodiments, thefirst and second markers 98 and 99 may be attached to the workpiece 82.For example, the first and second markers 98 and 99 may be attached tothe workpiece 82 using an adhesive and/or the first and second markers98 and 99 may be stickers. As a further example, the first and secondmarkers 98 and 99 may be clipped or clamped onto the workpiece 82. Thefirst and second markers 98 and 99 may have any suitable shape, size,and/or color. Furthermore, in certain embodiments, the first and secondmarkers 98 and 99 may be a reflector (e.g., retroreflector) formed froma reflective material. The first and second markers 98 and 99 may beused by the welding system 10 to calibrate the position and/ororientation of the workpiece 82 relative to the sensing device 16without a separate calibration device. Accordingly, the first and secondmarkers 98 and 99 are configured to be detected by the sensing device16. In certain embodiments, the first and second markers 98 and 99 maybe positioned at predetermined locations on the workpiece 82.Furthermore, the welding software may be programmed to use thepredetermined locations to determine the position and/or the orientationof the workpiece 82. In other embodiments, the location of the first andsecond markers 98 and 99 may be provided to the welding software duringcalibration. With the first and second markers 98 and 99 on theworkpiece 82, the sensing device 16 may sense the position and/ororientation of the first and second markers 98 and 99 relative to thesensing device 16. Using this sensed data in conjunction with thelocation of the first and second markers 98 and 99 on the workpiece 82,the welding software may be able to calibrate the position and/ororientation of the workpiece 82 relative to the sensing device 16. Whilethe markers 95, 96, 98, and 99 have been described herein as beingdetected by the sensing device 16, in certain embodiments, the markers95, 96, 98, and 99 may indicate locations where a calibration device isto be touched for calibration using the calibration device, as describedpreviously.

The stand 12 includes a first arm 100 extending vertically from thewelding surface 88 and configured to provide support for the sensingdevice 16 and the display 32. A knob 101 is attached to the first arm100 and may be used to adjust an orientation of the sensing device 16relative to the first arm 100. For example, as the knob 101 is adjusted,mechanical components extending through the first arm 100 may adjust anangle of the sensing device 16. The display 32 includes a cover 102 toprotect the display 32 from welding emissions that may occur during alive welding operation. The cover 102 may be made from any suitablematerial, such as a transparent material, a polymer, and so forth. Byusing a transparent material, a welding operator may view the display 32while the cover 102 is positioned in front of the display 32, such asbefore, during, and/or after a welding operation. The sensing device 16may include a camera 104 coupled to the first arm 100 for recordingwelding operations. In certain embodiments, the camera 104 may be a highdynamic range (HDR) camera. Furthermore, the sensing device 16 mayinclude an emitter 105 coupled to the first arm 100. The emitter 105 maybe used to calibrate the position and/or orientation of the weldingsurface 88 relative to the sensing device 16. For example, the emitter105 may be configured to emit a visible pattern onto the welding surface88, the workpiece 82, the welding torch 14, or the operator, or anycombination thereof. That is, the pattern emitted by the emitter 105 isvisible to the camera 104. The emitter 105 may emit the visible patternat a desired wavelength, such as a wavelength in the infrared, visible,or ultraviolet spectrum (e.g., approximately 1 mm to 120 nm). Thevisible pattern may be shown onto the welding surface 88 and/or theworkpiece 82. Furthermore, the visible pattern may be detected by thesensing device 16 to calibrate the position and/or the orientation ofthe welding surface 88 relative to the sensing device 16. For example,based on particular features of the visible pattern alignments and/ororientations may be determined by the sensing device 16 and/or thewelding software. Moreover, the visible pattern emitted by the emitter105 may be used to facilitate positioning of the workpiece 82 on thewelding surface 88. As discussed in greater detail below, the visiblepattern may be detected by the sensing device 16 (e.g., camera 104) todetermine a shape (e.g., tube, S-shape, I-shape, U-shape) of theworkpiece 82, the operator, or position of the welding torch 14 prior towelding. In some embodiments, the visible pattern may be detected by thesensing device 16 during welding to detect workpiece 82, the operator,the welding torch 14, or any combination thereof.

In some embodiments, the one or more sensing devices 16 of the stand 12may include a second camera 109 coupled to a third arm 107 for recordingwelding operations in a similar manner to the camera 104. Furthermore, asecond emitter 113 coupled to the third arm 107 may emit a visiblepattern onto the welding surface 88, the workpiece 82, the welding torch14, or the operator, or any combination thereof. The second emitter 113may emit the visible pattern at a desired wavelength, such as awavelength in the infrared, visible, or ultraviolet spectrum. Thevisible pattern emitted from the second emitter 113 may be approximatelythe same wavelength or a different wavelength than the visible patternemitted by the emitter 105. As may be appreciated, the second camera 109and the second emitter 113 may be positioned to have a differentorientation (e.g., perpendicular, greater than approximately 5, 10, 20,30, 45, 50, 60, 75, or 80 or degrees or more) relative to the workpiece82 than the camera 104 and the emitter 105, thereby enabling thedetermination of the shape of the workpiece 82, the position of theoperator, or the position of the welding torch 14 in the event that thesensing device 16 of either arm 100, 107 is obscured from view of aportion of the welding environment. In some embodiments, the sensingdevices 16 may include multiple sets of cameras and emitters arranged atvarious points about the welding environment on or off the stand 12 tofacilitate the monitoring of the position and movement of objects in thewelding environment if one or more sensing devices are obscured fromview of the welding environment. As discussed in greater detail below,the receiver (e.g., camera 104) and the emitter 105 may be integratedwith the welding helmet 41, thereby enabling the training system 10 tomonitor the position and/or orientation of the welding torch 14 and theworkpiece relative to the welding helmet 41.

The stand 12 also includes a second arm 106 extending vertically fromthe welding surface 88 and configured to provide support for a weldingplate 108 (e.g., vertical welding plate, horizontal welding plate,overhead welding plate, etc.). The second arm 106 may be adjustable tofacilitate overhead welding at different heights. Moreover, the secondarm 106 may be manufactured in a number of different ways to facilitateoverhead welding at different heights. The welding plate 108 is coupledto the second arm 106 using a mounting assembly 110. The mountingassembly 110 facilitates rotation of the welding plate 108 asillustrated by arrow 111. For example, the welding plate 108 may berotated from extending generally in the horizontal plane (e.g., foroverhead welding), as illustrated, to extend generally in the verticalplane (e.g., for vertical welding). The welding plate 108 includes awelding surface 112. The welding surface 112 includes slots 114 that mayaid a welding operator in positioning the workpiece 82 on the weldingsurface 112, similar to the slots 91 on the welding surface 88. Incertain embodiments, the position of the workpiece 82 may be provided towelding software of the welding system 10 to calibrate the weldingsystem 10. For example, a welding operator may provide an indication tothe welding software identifying which slot 114 of the welding surface112 the workpiece 82 is aligned with. Furthermore, a predefined weldingassignment may direct the welding operator to align the workpiece 82with a particular slot 114. In certain embodiments, the workpiece 82 mayinclude an extension configured to extend into one or more of the slots114 for alignment of the workpiece 82 with the one or more slots 114. Asmay be appreciated, each of the slots 114 may be positioned at alocation corresponding to a respective location defined in the weldingsoftware.

The welding surface 112 also includes a first marker 116 and a secondmarker 118. The first and second markers 116 and 118 may be usedtogether to determine a position and/or an orientation of the weldingsurface 112. As may be appreciated, at least two markers are used todetermine the position and/or the orientation of the welding surface112. In certain embodiments, more than two markers may be used todetermine the position and/or the orientation of the welding surface112. The first and second markers 116 and 118 may be formed from anysuitable material. Moreover, in certain embodiments, the first andsecond markers 116 and 118 may be built into the welding surface 112 (oranother part of the welding plate 108), while in other embodiments, thefirst and second markers 116 and 118 may be attached to the weldingsurface 112 (or another part of the welding plate 108). For example, thefirst and second markers 116 and 118 may be attached to the weldingsurface 112 using an adhesive and/or the first and second markers 116and 118 may be stickers (e.g., tape). As a further example, the firstand second markers 116 and 118 may be clipped or clamped onto thewelding surface 112. In some embodiments, the first and second markers116 and 118 may be integrated into a holding clamp that is clamped ontoa welding coupon. The first and second markers 116 and 118 may have anysuitable shape, size, and/or color. Furthermore, in certain embodiments,the first and second markers 116 and 118 may be a reflector (e.g.,retroreflector) formed from a reflective material.

The first and second markers 116 and 118 may be used by the weldingsystem 10 to calibrate the position and/or orientation of the weldingsurface 112 relative to the sensing device 16 without a separatecalibration device. Accordingly, the first and second markers 116 and118 are configured to be detected by the sensing device 16. In certainembodiments, the first and second markers 116 and 118 may be positionedat predetermined locations on the welding surface 112. Furthermore, thewelding software may be programmed to use the predetermined locations todetermine the position and/or the orientation of the welding surface112. In other embodiments, the location of the first and second markers116 and 118 may be provided to the welding software during calibration.With the first and second markers 116 and 118 on the welding surface112, the sensing device 16 may sense the position and/or orientation ofthe first and second markers 116 and 118 relative to the sensing device16. Using this sensed data in conjunction with the location of the firstand second markers 116 and 118 on the welding surface 112, the weldingsoftware may be able to calibrate the position and/or orientation of thewelding surface 112 relative to the sensing device 16. Furthermore, thesensing device 16 may sense and/or track the first and second markers116 and 118 during a weld to account for any movement of the weldingplate 108 that may occur during the weld. While the markers 116 and 118have been described herein as being detected by the sensing device 16,in certain embodiments, the markers 116 and 118 may indicate locationswhere a calibration device is to be touched or inserted for calibrationusing the calibration device, as described previously.

FIG. 5 is a perspective view of an embodiment of a calibration device120. In some embodiments, the calibration device 120 is shaped like atorch and may be used for calibrating the position and/or orientation ofthe welding surfaces 88 and 112 relative to the sensing device 16. Inother embodiments, the calibration device 120 may be used forcalibrating the position and/or orientation of a welding joint. Thecalibration device 120 includes a handle 122 and a nozzle 124. Thenozzle 124 includes a pointed end 126 that may be used to touch alocation for calibration and/or to be inserted into an aperture forcalibration. The calibration device 120 also includes a user interface128 that enables the welding operator to provide input corresponding toa time that the calibration device 120 is touching a location forcalibration and/or is being inserted into an aperture for calibration.Moreover, in certain embodiments, the calibration device 120 includesmarkers 130 configured to be sensed by the sensing device 16. Asillustrated, the markers 130 extend from the calibration device 120.However, in other embodiments, the markers 130 may not extend from thecalibration device 120. The markers 130 may be any suitable markerconfigured to be detected by the sensing device 16 (e.g., camera).Moreover, the markers 130 may be any suitable size, shape, and/or color.

During calibration, the sensing device 16 may sense a position of thecalibration device 120 and/or an orientation of the calibration device120. The position and/or orientation of the calibration device 120 maybe used by the welding software to determine a position and/ororientation of one or more of the welding surfaces 88 and 112 relativeto the sensing device 16, a position and/or orientation of the workpiece82 relative to the sensing device 16, a position and/or orientation of afixture relative to the sensing device 16, and so forth. Thus, thecalibration device 120 may facilitate calibration of the welding system10. In some embodiments, a tray may be positioned beneath the weldingsurface 88 for storing the calibration device 120. Moreover, in certainembodiments live welding may be disabled if the calibration device 120is able to be tracked by the sensing device 16 (e.g., to block spatterfrom contacting the calibration device 120).

FIG. 6 is a perspective view of an embodiment of a fixture assembly 132.The fixture assembly 132 may be positioned on the welding surface 88and/or the welding surface 112, and may secure the workpiece 82 thereon.In certain embodiments, the fixture assembly 132 may be configured toalign with one or more of the slots 92 and 114. In other embodiments,the fixture assembly 132 may be placed at any location on the weldingsurface 88 and/or the welding surface 122. The fixture assembly 132 alsoincludes a first marker 134 and a second marker 136. The first andsecond markers 134 and 136 may be used together to determine a positionand/or an orientation of the fixture assembly 132. As may beappreciated, at least two markers are used to determine the positionand/or the orientation of the fixture assembly 132. The first and secondmarkers 134 and 136 may be formed from any suitable material. Moreover,in certain embodiments, the first and second markers 134 and 136 may bebuilt into the fixture assembly 132, while in other embodiments, thefirst and second markers 134 and 136 may be attached to the fixtureassembly 132. For example, the first and second markers 134 and 136 maybe attached to the fixture assembly 132 using an adhesive and/or thefirst and second markers 134 and 136 may be stickers (e.g., tape). Thefirst and second markers 134 and 136 may have any suitable shape, size,and/or color. Furthermore, in certain embodiments, the first and secondmarkers 134 and 136 may be a reflector (e.g., retroreflector) formedfrom a reflective material. The first and second markers 134 and 136 maybe used by the welding system 10 to calibrate the position and/ororientation of the fixture assembly 132 relative to the sensing device16 without a separate calibration device. Accordingly, the first andsecond markers 134 and 136 are configured to be detected by the sensingdevice 16. In certain embodiments, the first and second markers 134 and136 may be positioned at predetermined locations on the fixture assembly132. Furthermore, the welding software may be programmed to use thepredetermined locations to determine the position and/or the orientationof the fixture assembly 132. In other embodiments, the location of thefirst and second markers 134 and 136 may be provided to the weldingsoftware during calibration. With the first and second markers 134 and136 on the fixture assembly 132, the sensing device 16 may sense theposition and/or orientation of the first and second markers 134 and 136relative to the sensing device 16. Using this sensed data in conjunctionwith the location of the first and second markers 134 and 136 on thefixture assembly 132, the welding software may be able to calibrate theposition and/or orientation of the fixture assembly 132 relative to thesensing device 16. While the first and second markers 134 and 136 havebeen described herein as being detected by the sensing device 16, incertain embodiments, the first and second markers 134 and 136 mayindicate locations where a calibration device is to be touched orinserted for calibration using the calibration device 120, as describedpreviously.

In the illustrated embodiment, the fixture assembly 132 is configured tosecure a lower portion 138 of the workpiece 82 to an upper portion 140of the workpiece 82 for performing a lap weld. In other embodiments, thefixture assembly 132 may be configured to secure portions of theworkpiece 82 for performing a butt weld, a fillet weld, and so forth, toaid a welding operator in performing a weld. The fixture assembly 132includes vertical arms 142 extending from a base 143. A cross bar 144extends between the vertical arms 142, and is secured to the verticalarms 142. Adjustment mechanisms 146 (e.g., knobs) may be adjusted todirect locking devices 148 toward the workpiece 82 for securing theworkpiece 82 between the locking devices 148 and the base 143 of thefixture assembly 132. Conversely, the adjustment mechanisms 146 may beadjusted to direct the locking devices 148 away from the workpiece 82for removing the workpiece 82 from being between the locking devices 148and the base 143. Accordingly, the workpiece 82 may be selectivelysecured to the fixture assembly 132.

FIG. 7 is a perspective view of a welding wire stickout calibration tool150. The tool 150 is configured to calibrate a length of welding wireextending out of a torch nozzle to a selectable length. Accordingly, thetool 150 includes a first handle 152 and a second handle 154. The tool150 also includes a torch nozzle holder 156 attached to a centralportion 157 of the tool 150 and extending outward from the centralportion 157 a selected distance. In the illustrated embodiment, thetorch nozzle holder 156 has a generally cylindrical body 158 (e.g., cupshape); however, in other embodiments, the body 158 of the torch nozzleholder 156 may have any suitable shape. Moreover, the torch nozzleholder 156 is configured to receive the torch nozzle through a nozzleinlet 160 such that the torch nozzle extends into the body 158.Furthermore, the torch nozzle holder 156 includes an opening 162configured to enable welding wire to extend out the end of the torchnozzle holder 156, and to block the torch nozzle from extending throughthe opening 162. As the torch nozzle extends into the torch nozzleholder 156, the welding wire extends out of the opening 162 of the torchnozzle holder 156 toward a blade assembly 164 of the tool 150. The bladeassembly 164 includes one or more sides 165 and 166 configured tocontact the welding wire. In certain embodiments, both of sides 165 and166 include blades to cut opposing sides of the welding wire, while inother embodiments, only one of the sides 165 and 166 includes a blade tocut one side of the welding wire and the other side includes a surfaceto which the blade is directed toward. For calibrating the length of thewelding wire, the welding wire may extend through the opening 162 andinto the blade assembly 164. The welding wire may be cut to a selectablelength by pressing the first handle 152 and the second handle 154 towardone another, thereby calibrating the length of wire extending from thetorch nozzle. The calibration length may be selected using an adjustmentmechanism 167 to adjust a distance 168 between the blade assembly 164and the opening 162 of the torch nozzle holder 156. Thus, using the tool150, the length of wire extending from the torch nozzle may becalibrated.

FIG. 8 is a top view of the welding wire stickout calibration tool 150of FIG. 7. As illustrated, the welding torch 14 may be used with thetool 150. Specifically, a nozzle 170 of the welding torch 14 may beinserted into the torch nozzle holder 156 in a direction 172. Weldingwire 174 extending from the welding torch 14 is directed through thenozzle inlet 160, the opening 162, and the blade assembly 164.Accordingly, the first and second handles 152 and 154 may be pressedtogether to cut the welding wire 174 to the distance 168 (e.g., thecalibration length) set by the adjustment mechanism 167.

FIG. 9 is an embodiment of a method 176 for calibrating wire stickoutfrom the welding torch 14. The tool 150 may be used to calibrate thelength of welding wire 174 extending from the nozzle 170 using a varietyof methods. In the method 176, the adjustment mechanism 167 of thewelding wire stickout calibration tool 150 may be adjusted for aselected welding wire 174 length (block 178). For example, the distance168 of the torch nozzle holder 156 from the tool 150 may be set to arange of between approximately 0.5 to 2.0 cm, 1.0 to 3.0 cm, and soforth. The welding torch 14 may be inserted into the torch nozzle holder156 of the tool 150, such that the nozzle 170 of the welding torch 14abuts the torch nozzle holder 156, and that the welding wire 174 extendsthrough the opening 162 of the torch nozzle holder 156 (block 180). Incertain embodiments, the welding wire 174 may be long enough to extendthrough the blade assembly 164. However, if the welding wire 174 doesnot extend through the blade assembly 164, a welding operator mayactuate the trigger 70 of the welding torch 14 to feed welding wire 174such that the welding wire 174 extends through the blade assembly 164(block 182). Accordingly, the welding operator may compress handles 152and 154 of the tool 150 to cut the welding wire 174 extending throughthe blade assembly 164 and thereby calibrate the length of the weldingwire 174 (block 184).

FIG. 10 is a perspective view of an embodiment of a welding consumable186 having physical marks. The welding consumable 186 may be anysuitable welding consumable, such as a welding stick, welding rod, or awelding electrode. The welding consumable 186 includes physical marks188, 190, 192, 194, 196, 198, 200, 202, and 204. The physical marks 188,190, 192, 194, 196, 198, 200, 202, and 204 may be any suitable physicalmark. For example, the physical marks 188, 190, 192, 194, 196, 198, 200,202, and 204 may include a bar code, an image, a shape, a color, text, aset of data, and so forth. In certain embodiments, the physical marks188, 190, 192, 194, 196, 198, 200, 202, and 204 may be laser etched.Furthermore, in certain embodiments, the physical marks 188, 190, 192,194, 196, 198, 200, 202, and 204 may be visible with the natural eye(e.g., within the visible spectrum), while in other embodiments thephysical marks 188, 190, 192, 194, 196, 198, 200, 202, and 204 may notbe visible with the natural eye (e.g., not within the visible spectrum).

Each of the physical marks 188, 190, 192, 194, 196, 198, 200, 202, and204 indicates a location on the welding consumable 186 relative toeither a first end 206, or a second end 208 of the welding consumable186. For example, the physical mark 188 may indicate a distance from thefirst end 206, a distance from the second end 208, or some otherlocation relative to the welding consumable 186. In certain embodiments,the physical marks 188, 190, 192, 194, 196, 198, 200, 202, and 204 mayindicate a number that corresponds to the first end 206 and/or thesecond end 208. For example, the physical mark 188 may indicate a number“1” indicating that it is the first physical mark from the first end 206and/or the physical mark 188 may indicate a number “9” indicating thatit is the ninth physical mark from the second end 208. A processingdevice may use a lookup table to determine a distance from the first end206 or the second end 208 based on the number indicated by the physicalmark.

A camera-based detection system, which may include the sensing device16, or another type of system is configured to detect the physical marks188, 190, 192, 194, 196, 198, 200, 202, and 204 during live arc weldingor a welding simulation. Moreover, the camera-based detection system isconfigured to determine a remaining length of the welding consumable186, a consumed length of the welding consumable 186, a rate of use ofthe welding consumable 186, a dipping rate of the welding consumable186, and so forth, based on the detected physical marks. Accordingly,data corresponding to use of the welding consumable 186 may be trackedby the welding system 10 for training and/or analysis.

FIG. 11 is a perspective view of an embodiment of welding wire 210having physical marks 212, 214, 216, and 218. The physical marks 212,214, 216, and 218 may be any suitable physical mark. For example, thephysical marks 212, 214, 216, and 218 may include a bar code, an image,a shape, text, a set of data, and so forth. In certain embodiments, thephysical marks 212, 214, 216, and 218 may be laser etched. Furthermore,in certain embodiments, the physical marks 212, 214, 216, and 218 may bevisible with the natural eye (e.g., within the visible spectrum), whilein other embodiments the physical marks 212, 214, 216, and 218 may notbe visible with the natural eye (e.g., not within the visible spectrum).

Each of the physical marks 212, 214, 216, and 218 indicates a locationon the welding wire 210 relative to either a first end 220, or a secondend 222 of the welding wire 210. For example, the physical mark 212 mayindicate a distance from the first end 220, a distance from the secondend 222, or some other location relative to the welding wire 210. Incertain embodiments, the physical marks 212, 214, 216, and 218 mayindicate a number that corresponds to the first end 220 and/or thesecond end 222. For example, the physical mark 212 may indicate a number“1” indicating that it is the first physical mark from the first end 220and/or the physical mark 212 may indicate a number “4” indicating thatit is the fourth physical mark from the second end 222. A processingdevice may use a lookup table to determine a distance from the first end220 or the second end 222 based on the number indicated by the physicalmark.

A camera-based detection system, which may include the sensing device16, or another type of system is configured to detect the physical marks212, 214, 216, and 218 during live arc welding or a welding simulation.Moreover, the camera-based detection system is configured to determine aremaining length of the welding wire 210, a consumed length of thewelding wire 210, a rate of use of the welding wire 210, a dipping rateof the welding wire 210, and so forth, based on the detected physicalmarks. Accordingly, data corresponding to use of the welding wire 210may be tracked by the welding system 10 for training and/or analysis.

FIG. 12 is a perspective view of an embodiment of a vertical armassembly 223 of the stand 12 of FIG. 4. As illustrated, the sensingdevice 16 is attached to the first arm 100. Furthermore, the sensingdevice 16 includes cameras 224, and an infrared emitter 226. However, inother embodiments, the sensing device 16 may include any suitable numberof cameras, emitters, and/or other sensing devices. A pivot assembly 228is coupled to the first arm 100 and to the sensing device 16, andenables an angle of the sensing device 16 to be adjusted while thesensing device 16 rotates as illustrated by arrow 229. As may beappreciated, adjusting the angle of the sensing device 16 relative tothe first arm 100 changes the field of view of the sensing device 16(e.g., to change the portion of the welding surface 88 and/or thewelding surface 112 sensed by the sensing device 16). In someembodiments, the sensing device 16 may be arranged to observe at least aportion (e.g., hands, face) of the operator prior to and/or aftercompletion of a weld process. Observation of the operator by the sensingdevice 16, such as by a camera, may facilitate operator identificationand verification that the identified operator performed the observedweld process.

A cord 230 extends between the knob 101 and the sensing device 16. Thecord 230 is routed through a pulley 232 to facilitate rotation of thesensing device 16. Thus, a welding operator may rotate the knob 101 tomanually adjust the angle of the sensing device 16. As may beappreciated, the combination of the cord 230 and the pulley 232 is oneexample of a system for rotating the sensing device 16. It should benoted that any suitable system may be used to facilitate rotation of thesensing device 16. While one embodiment of a knob 101 is illustrated, itmay be appreciated that any suitable knob may be used to adjust theangle of the sensing device 16. Furthermore, the angle of the sensingdevice 16 may be adjusted using a motor 234 coupled to the cord 230.Acordingly, a welding operator may operate the motor 234 to adjust theangle of the sensing device 16. Moreover, in certain embodiments,control circuitry may be coupled to the motor 234 and may control theangle of the sensing device 16 based on a desired field of view of thesensing device 16 and/or based on tracking of an object within the fieldof view of the sensing device 16.

FIG. 13 is a perspective view of an embodiment of an overhead weldingarm assembly 235. The overhead welding arm assembly 235 illustrates oneembodiment of a manufacturing design that enables the second arm 106 tohave an adjustable height. Accordingly, as may be appreciated, thesecond arm 106 may be manufactured to have an adjustable height in anumber of ways. As illustrated, the overhead welding assembly 235includes handles 236 used to vertically raise and/or lower the secondarm 106 as illustrated by arrows 238. The overhead welding arm assembly235 includes a locking device 240 to lock the second arm 106 at adesired height. For example, the locking device 240 may include a buttonthat is pressed to disengage a latch configured to extend into openings242, thus unlocking the second arm 106 from being secured to side rails243. With the second arm 106 unlocked from the side rails 243, thehandles 236 may be vertically adjusted to a desired height, therebyadjusting the plate 112 to a desired height. As may be appreciated,releasing the button may result in the latch extending into the openings242 and locking the second arm 106 to the side rails 243. As may beappreciated, the locking device 240 may operate manually as describedand/or the locking device 240 may be controlled by a control system(e.g., automatically controlled). Furthermore, the second arm 106 may bevertically raised and/or lowered using the control system. For example,in certain embodiments, the welding software may control the second arm106 to move to a desired position automatically. Thus, the plate 112 maybe adjusted to a desired height for overhead welding.

FIG. 14 is a block diagram of an embodiment of welding software 244(e.g., welding training software) of the welding system 10 havingmultiple modes. As illustrated, the welding software 244 may include oneor more of a live-arc mode 246 configured to enable training using alive (e.g., actual) welding arc, a simulation mode 248 configured toenable training using a welding simulation, a virtual reality (VR) mode250 configured to enable training using a VR simulation, and/or anaugmented reality mode 252 configured to enable training using augmentedreality simulation.

The welding software 244 may receive signals from an audio input 254.The audio input 254 may be configured to enable a welding operator tooperate the welding software 244 using audible commands (e.g., voiceactivation). Furthermore, the welding software 244 may be configured toprovide an audio output 256 and/or a video output 258. For example, thewelding software 244 may provide audible information to a weldingoperator using the audio output 256. Such audible information mayinclude instructions for configuring (e.g., setting up) the weldingsystem 10, real-time feedback provided to a welding operator during awelding operation, instructions to a welding operator before performinga welding operation, instructions to a welding operator after performinga welding operation, warnings, and so forth.

FIG. 15 is a block diagram of an embodiment of the VR mode 250 of thewelding software 244. The VR mode 250 is configured to provide a weldingoperator with a VR simulation 260. The VR simulation 260 may bedisplayed to a welding operator through a VR headset, VR glasses, a VRdisplay, or any suitable VR device. In some embodiments, the display 32of the helmet 41 of the welding system 10 may facilitate the VRsimulation 260. The VR simulation 260 may be configured to include avariety of virtual objects, such as the objects illustrated in FIG. 15,that enable interaction between a welding operator and a selectedvirtual object of the variety of virtual objects within the VRsimulation 260. For example, virtual objects may include a virtualworkpiece 262, a virtual welding stand 264, a virtual welding torch 266,virtual wire cutters 268, virtual software configuration 270, virtualtraining data results 272, and/or a virtual glove 274.

In certain embodiments, the welding operator may interact with thevirtual objects without touching a physical object. For example, thesensing device 16 may detect movement of the welding operator and mayresult in similar movements occurring in the VR simulation 260 based onthe welder operator's movements in the real world. In other embodiments,the welding operator may use a glove or the welding torch 14 to interactwith the virtual objects. For example, the glove or the welding torch 14may be detected by the sensing device 16, and/or the glove or thewelding torch 14 may correspond to a virtual object in the VR simulation260. Furthermore, the welding operator may be able to operate thewelding software 244 within the VR simulation 260 using the virtualsoftware configuration 270 and/or the virtual training data results 272.For example, the welding operator may use their hand, the glove, or thewelding torch 14 to select items within the welding software 244 thatare displayed virtually within the VR simulation 260. Moreover, thewelding operator may perform other actions such as picking up wirecutters and cutting virtual welding wire extending from the virtualtorch 266, all within the VR simulation 260.

FIG. 16 is an embodiment of a method 276 for integrating trainingresults data, non-training results data, simulation results data, and soforth. The method 276 includes the welding software 244 of the computer18 receiving a first set of welding data from a storage device (e.g.,storage device 24) (block 278). The first set of welding data mayinclude welding data corresponding to a first welding session (e.g.,welding assignment). The method 276 also includes the welding software244 receiving a second set of welding data from the storage device(block 280). In certain embodiments, the first set and/or second set ofwelding data may be received from a network storage device. The networkstorage device may be configured to receive welding data from and/or toprovide welding data to the welding system 10 and/or the externalwelding system 40. The welding software 244 may integrate the first andsecond sets of welding data into a chart to enable a visual comparisonof the first set of welding data with the second set of welding data(block 282). As may be appreciated, the chart may be a bar chart, a piechart, a line chart, a histogram, and so forth. In certain embodiments,integrating the first set of welding data with the second set of weldingdata includes filtering the first set of welding data and the second setof welding data to display a subset of the first set of welding data anda subset of the second set of welding data. The welding software 244 mayprovide the chart to a display device (e.g., the display 32) (block284). In certain embodiments, providing the chart to the display deviceincludes providing selectable elements on the chart that when selecteddisplay data corresponding to a respective selected element of theselectable elements (e.g., selecting wire speed from the chart maychange the screen to display the wire speed history for a particularwelding session (e.g., welding assignment)).

The first set of welding data and/or the second set of welding data mayinclude a welding torch orientation, a welding torch travel speed, awelding torch position, a contact tip to workpiece distance, an aim ofthe welding torch, a welding score, a welding grade, and so forth.Moreover, the first set of welding data and the second set of weldingdata may correspond to training performed by one welding operator and/orby a class of welding operators. Furthermore, the first welding session(e.g., welding assignment) and the second welding session (e.g., weldingassignment) may correspond to training performed by one welding operatorand/or by a class of welding operators. In certain embodiments, thefirst welding assignment may correspond to training performed by a firstwelding operator, and the second welding assignment may correspond towelding performed by a second welding operator. Moreover, the firstassignment and the second assignment may correspond to the same weldingscenario. Additionally, or in the alternative, the first set of weldingdata and the second set of welding data may correspond to weldingsessions (e.g., welding assignments) performed by one welding operatorand/or a class of welding operators outside of a training environment(e.g., production floor).

FIG. 17 is an embodiment of a chart 285 illustrating multiple sets ofwelding data for a welding operator. The chart 285 may be produced bythe welding software 244 and may be provided to the display 32 to beused by a welding instructor to review welding operations performed by awelding student, and/or may be provided to the display 32 to be used bya welding student to review welding operations performed by that weldingstudent. The chart 285 illustrates a bar graph comparison betweendifferent sessions (e.g., assignments) of a first set of weldingassignments performed by a welding operator. The first set of weldingsessions (e.g., welding assignments) includes sessions (e.g.,assignments) 286, 288, 290, 292, and 294. The chart 285 also illustratesa bar graph comparison between different assignments of a second set ofwelding sessions (e.g., welding assignments) performed by the weldingoperator. The second set of welding sessions (e.g., welding assignments)includes sessions (e.g., assignments) 296, 298, 300, 302, and 304.Accordingly, welding sessions (e.g., welding assignments) may becompared to one another for analysis, instruction, certification, and/ortraining purposes. As illustrated, the welding sessions (e.g., weldingassignments) may be compared to one another using one of any number ofcriteria, such as a total score, a work angle, a travel angle, a travelspeed, a contact to work distance, an aim, a mode (e.g., live-arc mode,simulation mode, etc.), a completion status (e.g., complete, incomplete,partially complete, etc.), a joint type (e.g., fillet, butt, T, lap,etc.), a welding position (e.g., flat, vertical, overhead, etc.), a typeof metal used, a type of filler metal, and so forth.

The welding software 244 may associate an operator with welding data(e.g., arc parameters, welding parameters) acquired during a weldingsession (e.g., live arc welding assignment, simulated weldingassignment, and so forth). For example, the welding software 244 mayidentify the welding operator by an operator name 291, an operatorregistration number 293, an operator photograph 295, and so forth. Forexample, the operator identification system 43 discussed above with FIG.1 may be utilized to determine the operator registration number 293.That is, each operator registration number 293 may correspond to theoperator name 291 and a set of identification information (e.g.,resettable information 45, biometric information 47, token 49). In someembodiments, the registration number 293 may be reset or reassigned toanother operator after a period (e.g., 1, 3, 5, 10, or more years) ofinactivity associated with the registration number 293. The registrationnumber 293 may be unique for each operator. In some embodiments, theregistration number 293 may be retained by the operator for an extendedperiod of time (e.g., career, life) regardless of activity levelassociated with the registration number 293. That is, the registrationnumber 293 may be a permanent identifier associated with each operatoracross one welding system 10 or a network of welding systems 10 coupledvia the network 38. Welding data associated with the registration number293 may be maintained locally or within one or more data storagesystems, such as a cloud storage system or database of the network 38coupled to the welding system 10. The data storage system 318 (e.g.,cloud storage system) of the network 38 may be maintained by themanufacturer or another party, thereby enabling the welding dataassociated with a certain registration number 293 to be retainedindependent of an employment status of the operator with the certainregistration number 293. For example, the operator registration number293 and the data storage system (e.g., cloud storage system) mayfacilitate the retention of welding data associated with the operatorfrom weld processes performed during training, during a simulation,during a first employment, during a second employment, during personaltime, or any combination thereof. In some embodiments, welding datastored within the memory 22 or the storage 24 of the computer 18 of thewelding system 10 for a particular welding operator (e.g., operatorregistration number 293) may be selectively or automaticallysynchronized with the data storage system (e.g., cloud storage system).

Weld history data, such as the data of the chart 285, is associated witheach registration number 293. In some embodiments, the weld history datais automatically acquired and stored in the data storage system (e.g.,cloud storage system) by the welding software 244 of the welding system10. Additionally, or in the alternative, weld history data may be loadeddirectly to the data storage system (e.g., cloud storage system) of thenetwork 38 via a remote computer 44. The welding software 244 mayfacilitate access to the welding history data via a welding historycontrol 297. Additionally, the welding software 244 may enable theoperator to associate personal information with the registration number293 via a personal user control 299. The operator associated with theregistration number 293 may input one or more organizations (e.g.,training center, school, employer, trade organization) with which theoperator is affiliated, experience, certifications for various weldingprocesses and/or welding positions, a résumé, or any combinationthereof. Furthermore, the registration umber 293 may remain associatedwith the operator despite changes in affiliated organizations,experience, certifications, or any combination thereof.

FIG. 18 is an embodiment of a chart 305 illustrating welding data for awelder compared to welding data for a class. For example, the chart 305illustrates a score 306 of a welding operator compared to a score 308(e.g., average, median, or some other score) of a class for a firstassignment. Furthermore, a score 310 of the welding operator is comparedto a score 312 (e.g., average, median, or some other score) of the classfor a second assignment. Moreover, a score 314 of the welding operatoris compared to a score 316 (e.g., average, median, or some other score)of the class for a third assignment. As may be appreciated, scores fromone or more welding operators may be compared to scores of the entireclass. Such a comparison enables a welding instructor to assess theprogress of individual welding students as compared to the class ofwelding students. Furthermore, scores from one or more welding operatorsmay be compared to scores of one or more other welding operators. Incertain embodiments, scores from one class may be compared to scores ofanother class. Moreover, scores from the first assignment, the secondassignment, and/or the third assignment may be selected for comparison.

FIG. 19 is a block diagram of an embodiment of a data storage system 318(e.g., cloud storage system) for storing welding data 327, such ascertification status data 326. The data storage system 318 may include,but is not limited to, the computer 18 of the welding system 10, aremote computer 44 (e.g., server) coupled to the welding system 10 viathe internet or a network 38, or any combination thereof. Thecertification status data may be produced as a welding operatorcompletes various assignments in the welding system 10. For example, apredetermined set of assignments may certify a welding operator for aparticular welding device and/or welding process. The data storagesystem 318 (e.g., cloud storage system) includes control circuitry 320,one or more memory devices 322, and one or more storage devices 324. Thecontrol circuitry 320 may include one or more processors, which may besimilar to the processor(s) 20. Furthermore, the memory device(s) 322may be similar to the memory device(s) 22, and the storage device(s) 324may be similar to the storage device(s) 24. The memory device(s) 322and/or the storage device(s) 324 may be configured to storecertification status data 326 corresponding to a welding certification(e.g., welding training certification) of a welding operator.

The welding data 327 may include any data acquired by the welding system10 associated with the registration number 293 of the welding operator(e.g., any data that is related to the assignments to certify thewelding operator, training welding data, simulated welding data, virtualreality welding data, live welding data), any data related to an actualcertification (e.g., certified, not certified, qualified, not qualified,etc.), a quantity of one or more welds performed by the weldingoperator, a timestamp for one or more welds performed by the weldingoperator, a location and/or facility that the welding operator performsthe one or more welds, the components of the welding system utilized bythe welding operator for the one or more welds, the organization withwhich the welding operator is affiliated, the organization for whom thewelding operator is performing the one or more welds, welding parameterdata for one or more welds performed by the welding operator, a qualityranking of the welding operator, a quality level of the weldingoperator, a history of welds performed by the welding operator, ahistory of production welds performed by the welding operator, a firstwelding process (e.g., a metal inert gas (MIG) welding process, atungsten inert gas (TIG) welding process, a stick welding process, etc.)certification status (e.g., the welding operator is certified for thefirst welding process, the welding operator is not certified for thefirst welding process), a second welding process certification status(e.g., the welding operator is certified for the second welding process,the welding operator is not certified for the second welding process), afirst welding device (e.g., a wire feeder, a power supply, a modelnumber, etc.) certification status (e.g., the welding operator iscertified for the first welding device, the welding operator is notcertified for the first welding device), and/or a second welding devicecertification status (e.g., the welding operator is certified for thesecond welding device, the welding operator is not certified for thesecond welding device).

The control circuitry 320 may be configured to receive a request for thefirst welding process certification status, the second welding processcertification status, the first welding device certification status,and/or the second welding device certification status of the weldingoperator. Furthermore, the control circuitry 320 may be configured toprovide a response to the request. The response to the request mayinclude the first welding process certification status, the secondwelding process certification status, the first welding devicecertification status, and/or the second welding device certificationstatus of the welding operator. In certain embodiments, the weldingoperator may be authorized to use a first welding process, a secondwelding process, a first welding device, and/or a second welding devicebased at least partly on the response. Furthermore, in some embodiments,the first welding process, the second welding process, the first weldingdevice, and/or the second welding device of a welding system may beenabled or disabled based at least partly on the response. Moreover, incertain embodiments, the first welding process, the second weldingprocess, the first welding device, and/or the second welding device of awelding system may be enabled or disabled automatically. Thus, a weldingoperator's certification data may be used to enable and/or disable thatwelding operator's ability to use a particular welding system, weldingdevice, and/or welding process. For example, a welding operator may havea certification for a first welding process, but not for a secondwelding process. Accordingly, in certain embodiments, a welding operatormay verify their identity at a welding system (e.g., by logging in, byutilizing the operator identification system 43, providing theregistration number 293, or some other form of authentication). Afterthe identity of the welding operator is verified, the welding system maycheck the welding operator's certification status. The welding systemmay enable the welding operator to perform operations using the firstwelding process based on the welding operator's certification status,but may block the welding operator from performing the second weldingprocess based on the welding operator's certification status.

The storage 324 of the data storage system 318 (e.g., cloud storagesystem) may have welding data 327 of multiple operators. The datastorage system 318 may be a database that retains welding data 327associated with registration numbers 293 to enable analysis and trackingof the weld history of the operator over extended durations (e.g.,career, lifetime), even across one or more organizations. As may beappreciated, the data storage system 318 (e.g., cloud storage system)may facilitate aggregation of certification status data 326 and/orwelding data 327 to identify usage trends, anticipate supply ormaintenance issues, and so forth. Moreover, coupling the data storagesystem 318 to the internet or other network 38 enables instructors ormanagers to monitor and analyze weld data remote from the operator andthe respective welding system 10.

FIG. 20 is an embodiment of a screen illustrating data corresponding toa weld by an operator identified on the screen by the registrationnumber 293. In some embodiments, each weld session (e.g., weld test,assignment) performed by an operator and monitored by the welding system10 is assigned a unique serial number 329. The serial number 329 may beassociated with the registration number 293 within one or more localand/or remote data storage systems, such as a cloud storage system ordatabase of the network 38 coupled to the welding system 10. The serialnumber 329 may be used to associate the physical weld sample with thecaptured weld test results. The format of the serial number 329 mayinclude, but is not limited to a decimal number, a hexadecimal number,or a character string. Moreover, the serial numbers 329 for the sameassignment may be different for each operator. In some embodiments, atleast a portion of the serial number may be based at least in part onspecific components of the welding system 10. For example, the serialnumber for assignments completed with a particular welding system mayhave digits corresponding to serial numbers of the particular powersupply 28, the particular wire feeder 30, and/or the particular weldingtorch 14 utilized for the welding assignment. In some embodiments, theserial number 329 is affixed to the workpiece 82. For example, theserial number 329 may attached to, stamped, etched, engraved, embossed,or printed on the workpiece 82. In some embodiments, the serial number329 is encoded as a barcode affixed to the workpiece 82. Additionally,or in the alternative, the operator may write the serial number 329 onthe workpiece 82.

As discussed below, a search feature enables an instructor to enter theserial number 329 to recall the test results for the associated weldsession (e.g., weld test, assignment) without the instructor needing toknow the user (e.g., registration number 293), the assignment, or anyother details about the weld. Accordingly, the instructor may review thedata corresponding to each serial number 329, then provide feedback tothe respective operator. The data corresponding to each serial number329 may be reviewed locally via the welding system 10 on which the datawas initially acquired, or remotely via another welding system 10 or acomputer 18 coupled to the data storage system 318 with the data storedtherein. Furthermore, an inspector or technician may review the serialnumber 329 of a workpiece 82 to aid in a quality review of the performedweld relative to welding procedure specifications (WPS) and/or todetermine a maintenance schedule related to the workpiece 82. That is,the serial number 329 may be utilized to track the workpiece 82, thewelding data, the arc data, and the operator (e.g., registration number293) through a life of the respective workpiece 82. In some embodiments,the serial number 329 may be stored within one or more local and/orremote data storage systems, such as a cloud storage system or databaseof the network 38 coupled to the welding system 10. The screen may beproduced by the welding software 244 and may be displayed on the display32. The screen illustrates parameters that may be graphically displayedto a welding operator before, during, and/or after performing a weldingoperation. For example, the parameters may include a work angle 328, atravel angle 330, a contact tip to workpiece distance 332, a weldingtorch travel speed 334, an aim of the welding torch in relation to thejoint of the workpiece 336, a welding voltage 337, a welding current338, a welding torch orientation, a welding torch position, and soforth.

As illustrated, graphically illustrated parameters may include anindication 339 of a current value of a parameter (e.g., while performinga welding session). Furthermore, a graph 340 may show a history of thevalue of the parameter, and a score 341 may show an overall percentagethat corresponds to how much time during the welding session that thewelding operator was within a range of acceptable values. In certainembodiments, a video replay 342 of a welding session may be provided onthe screen. The video replay 342 may show live video of a weldingoperator performing a real weld, live video of the welding operatorperforming a simulated weld, live video of the welding operatorperforming a virtual reality weld, live video of the welding operatorperforming an augmented reality weld, live video of a welding arc, livevideo of a weld puddle, and/or simulated video of a welding operation.

In certain embodiments, the welding system 10 may capture video dataduring a welding session (e.g., welding assignment), and store the videodata on the storage device 24 and/or the data storage system 318 (e.g.,cloud storage system) via the network 38. Moreover, the welding software244 may be configured to retrieve the video data from the storage device24 or the data storage system 318, to retrieve welding parameter datafrom the storage device 24 or the data storage system 318, tosynchronize the video data with the welding parameter data, and toprovide the synchronized video and welding parameter data to the display32.

In some embodiments, the welding system 10 may receive test data frompreviously performed welds. Test results 343 based at least in part onthe test data may be displayed on the screen. Test data may includeproperties of the performed welding session (e.g., welding assignment),such as strength, porosity, penetration, hardness, heat affected zonesize, appearance, and contamination, or any combination thereof. Thetest data may be obtained via destructive or non-destructive testingperformed after completion of the welding session. For example, strengthof a weld may be determined via a destructive test, whereas the porosityand penetration may be obtained via non-destructive testing, such asx-ray or ultrasonic inspection.

In some embodiments, the welding system 10 may determine the test data(e.g., properties of the welding assignment) based at least in part onwelding parameter data. Additionally, or in the alternative, the weldingsystem 10 may utilize arc parameter data to determine the test data. Thetest data (e.g., properties of the welding assignment) may be associatedwith the welding parameter data and any arc parameter data, such thatthe test data, welding parameter data, and arc parameter datacorresponding to the same welding session (e.g., welding assignment) arestored together. Where the welding session (e.g., welding assignment) isa live welding assignment, the arc parameters (e.g., weld voltage, weldcurrent, wire feed speed) may include measured arc parameters and/or setarc parameters. Where the welding session is a simulated, virtualreality, or augmented reality welding assignment, the arc parameters mayinclude simulated arc parameters. In some embodiments, the arcparameters associated with non-live welding sessions (e.g., simulated,virtual reality, augmented reality) may include a null set stored in thedata storage.

In some embodiments, the determined properties of the welding session(e.g., welding assignment) are based at least in part on a comparisonwith welding data (e.g., welding parameters, arc parameters)corresponding to previously performed welding sessions. The welding datacorresponding to previously performed welding sessions may be stored inthe data storage system 318. The welding system 10 may determine (e.g.,estimate, extrapolate) properties of a simulated welding assignment, avirtual reality welding assignment, or an augmented reality weldingassignment through comparison with welding data (e.g., weldingparameters, arc parameters) and associated test data corresponding topreviously performed live welding session (e.g., live weldingassignments). For example, the welding system 10 may determine thepenetration of a virtual reality welding assignment through comparisonof the welding parameters (e.g., contact tip to work distance, travelspeed) of the virtual reality welding assignment to the weldingparameters associated with previously performed live weldingassignments. Accordingly, the welding system 10 may facilitate trainingan operator through providing determined one or more properties of thewelding assignment despite the welding assignment (e.g., simulated,virtual reality, augmented reality) being performed without a tangibleworkpiece produced to test.

The computer 18 of the welding system 10 may determine one or moreproperties of the welding session (e.g., welding assignment) viaexecuting processor-executable instructions to compare the receivedwelding data with welding data corresponding to previously performedwelding sessions. In some embodiments, the one or more properties of thewelding session are determined remotely from the welding system 10, suchas on a remote computer 44 or data storage system 318 coupled to thewelding system 10 via the network 38. Additionally, or in thealternative, the one or more determined properties may be transmitted tothe data storage system 318, such as via the network 38. In someembodiments, the computer 18 may determine properties of the weldingsession (e.g., welding assignment) while receiving the welding dataassociated with the welding session. That is, the computer 18 maydetermine properties or quality characteristics (e.g., penetration,porosity, strength, appearance) substantially in real-time based atleast in part on the welding parameters while the operator is performingthe welding session. The determined properties may be displayed via thedisplay 32 as test results. As may be appreciated, the determinedproperties may be adjusted upon obtaining results from testing (e.g.,destructive testing, non-destructive testing) of the welding session(e.g., welding assignment).

The welding software 244 may analyze welding parameter data to determinea traversed path 344 that may be shown on the display 32. In someembodiments, a time during a weld may be selected by a welding operator,as shown by an indicator 346. By adjusting the selected time indicator346, the welding operator may view the video replay 342 and/or thetraversed path 344 in conjunction with the welding parameters as theywere at the selected time in order to establish a correlation betweenthe welding parameters, the video replay 342, and/or the traversed path344. Additionally, or in the alternative, the welding operator mayselect (e.g., via a cursor on the display 32, manual selection via atouch screen display 32) a location of the traversed path 344 displayedto review the welding data 327 corresponding to the one or more timesthe welding torch 14 traversed the selected location. Moreover, thevideo replay 342 may show frames of video (e.g., captured images,pictures) corresponding to the selected time 346 and/or selectedlocation. As may be appreciated, a selected location may correspond tomultiple frames or captured images when the welding operator utilized aweaving or whipping technique and/or when the welding session includesmultiple passes. Accordingly, the display 32 may show the multipleframes (e.g., captured images, pictures), and the welding operator mayselect one or more for additional review. In some embodiments, the testresults 343 (e.g., one or more determined properties of the weldingassignment) displayed may correspond to the selected time shown by theindicator 346 and/or to one or more locations along the traversed path344. That is, the test results 343 may display tested characteristics(e.g., porosity, penetration) of the weld corresponding to the selectedtime indicator 346 and/or the selected location along the traversed path344. The welding software 244 may be configured to recreate welding databased at least partly on welding parameter data, to synchronize thevideo replay 342 with the recreated welding data, and to provide thesynchronized video replay 342 and recreated welding data to the display32. In certain embodiments, the recreated welding data may be weldpuddle data and/or a simulated weld. In some embodiments, the weldingsoftware 244 may correlate various aspects (e.g., determined properties,video, non-destructive test results, destructive test results) of theweld data acquired for positions along the traversed path 344 of theweld and/or for selected times during the weld process. The weldingsoftware 244 may facilitate correlation of the welding parameters (e.g.,work angle 328, travel angle 330, CTWD 332, travel speed 334, and aim336 of the welding torch in relation to the joint of the workpiece, awelding torch orientation, a welding torch position) with arc parameters(e.g., voltage 337, current 338, wire feed speed), the video replay 342,and test results 343, or any combination thereof. The weld dataassociated with the registration number 293 for an operator may enablethe operator, the instructor, or a manager, to review the weldingparameters, the arc parameters, the video replay 342, and the testresults 343 (e.g., determined properties) corresponding to the selectedtime indicator 346 and/or position along the traversed path 344 of theweld process. For example, the operator may review the weld data toidentify relationships between changes in the welding parameters (e.g.,work angle 328, CTWD 332) and changes to the arc parameters (e.g.,current, voltage) at the selected time shown by the indicator 346 or aselected position. Moreover, the operator may review the weld data toidentify relationships between changes in the welding parameters andchanges to the test results 343 of the weld.

In some embodiments, the welding torch 14 (e.g., MIG welding torch,stick electrode holder, TIG torch) may be utilized as a pointer, wherepointing the welding torch 14 at a specific location of the welddisplays weld data 327 on the display 32 corresponding to the specificlocation. In some embodiments, the welding torch 14 may contact theworkpiece 82 at the specific location. Moreover, the welding software244 may determine the specific location from the operator based on thepoint along the weld that is nearest to where the operator is pointingthe welding torch 14 (e.g., electrode). The welding software 244 mayproduce a location bar 346 (e.g., indicator) to be displayed along theweld data 327 when the welding torch 14 is pointed at locations alongthe weld upon completion of the session. That is, the location bar mayextend across the graphs of the welding parameters (e.g., work angle328, travel angle 330, CTWD 332, travel speed 334, and aim 336 of thewelding torch in relation to the joint of workpiece) in a similar manneras the selected time line 346 described above and illustrated in FIG.20. The welding software 244 may be configured to display the videoreplay 342 (e.g., one or more video frames, captured images) that wascaptured when the welding torch 14 was at the specific location. Forexample, the welding software 244 may display between 0 to 30 framesbefore and/or after when the welding torch 14 was at the specificlocation. Additionally, or in the alternative, the welding software 244may display a cross-sectional view of the weld at the specific location.The cross-sectional view may be based on one or more sets of dataincluding, but not limited to, an x-ray scan, an ultrasonic scan, agenerated model based at least in part on the welding data 327, or anycombination thereof. Moreover, the cross-sectional view may enable thewelding operator or an instructor to review various determined qualitycharacteristics of the weld at the specific location, including, but notlimited to, porosity, undercut, spatter, underfill, and overfill. Whilethe welding torch 14 may be readily used to point to and select specificlocations of the weld before the workpiece 82 is moved upon completionof the session, the welding torch 14 may be used as a pointer forpreviously completed sessions with moved workpieces 82 uponrecalibration of respective workpieces 82. Moreover, in someembodiments, the calibration tool 610 or another welding device may beused to point to and select specific locations of the weld for whichvarious determined quality characteristics of the weld may be displayed.

In certain embodiments, the storage device 24 may be configured to storea first data set corresponding to multiple welds performed by a weldingoperator, and to store a second data set corresponding to multiplenon-training welds performed by the welding operator. Furthermore, thecontrol circuitry 320 may be configured to retrieve at least part of thefirst data set from the storage device 24, to retrieve at least part ofthe second data set from the storage device 24, to synchronize the atleast part of the first data set with the at least part of the seconddata set, and to provide the synchronized at least part of the firstdata set and at least part of the second data set to the display 32.

FIG. 21 is an embodiment of a screen 347 illustrating a discontinuityanalysis 348 of a weld. The discontinuity analysis 348 includes alisting 350 that may itemize potential issues with a welding operation.The discontinuity analysis 348 provides feedback to the welding operatorregarding time periods within the welding operation in which the welddoes not meet a predetermined quality threshold. For example, betweentimes 352 and 354, there is a high discontinuity (e.g., the weldingquality is poor, the weld has a high probability of failure, the weld isdefective). Furthermore, between times 356 and 358, there is a mediumdiscontinuity (e.g., the welding quality is average, the weld has amedium probability of failure, the weld is partially defective).Moreover, between times 360 and 362, there is a high discontinuity, andbetween times 364 and 366, there is a low discontinuity (e.g., thewelding quality is good, the weld has a low probability of failure, theweld is not defective). With this information a welding operator may beable to quickly analyze the quality of a welding operation.

FIG. 22 is a block diagram of an embodiment of a welding instructorscreen 368 of the welding software 244. The welding software 244 isconfigured to provide training simulations for many different weldingconfigurations. For example, the welding configurations may include aMIG welding process 370, a TIG welding process 372, a stick weldingprocess 374, the live-arc welding mode 346, the simulation welding mode248, the virtual reality welding mode 250, and/or the augmented realitywelding mode 252.

The welding instructor screen 368 may be configured to enable a weldinginstructor to restrict training of a welding operator 376 (e.g., to oneor more selected welding configurations), to restrict training of aclass of welding operators 378 (e.g., to one or more selected weldingconfigurations), and/or to restrict training of a portion of a class ofwelding operators 380 (e.g., to one or more selected weldingconfigurations). Moreover, the welding instructor screen 368 may beconfigured to enable the welding instructor to assign selected trainingassignments to the welding operator 382, to assign selected trainingassignments to a class of welding operators 384, and/or to assignselected training assignments to a portion of a class of weldingoperators 386. Furthermore, the welding instructor screen 368 may beconfigured to enable the welding instructor to automatically advance thewelding operator (or a class of welding operators) from a firstassignment to a second assignment 388. For example, the welding operatormay advance from a first assignment to a second assignment based atleast partly on a quality of performing the first assignment. Moreover,the welding instructor screen 368 may be configured to verify theidentity of an operator 389 (e.g., to ensure welding data is associatedwith the proper registration number 293). In some embodiments, theoperator identification system 43 identifies the operator, and theinstructor verifies the identity of the operator via the weldinginstructor screen 368. For example, the instructor may provide averification input (e.g., resettable identifier, biometric identifier,physical identifier) to the operator identification system 43 toauthorize that the identity of the operator is properly recognized bythe operator identification system 43. In some embodiments, theinstructor (e.g., second operator) provides a second identifier input(e.g., resettable identifier, biometric identifier, token) to thewelding system 10, such as via the operator identification system 43,thereby verifying the identity of the operator that provided a firstidentifier input to the operator identification system 43. The secondidentifier input may be stored with the welding data (e.g., identity ofoperator performing the welding session), such as in the memory 56 ofthe computer 18 or the data storage system 318). Additionally, or in thealternative, the welding instructor may verify the identity of anoperator 389 via a two-step identification process in which the operatoridentification system 43 separately identifies both the operator and theinstructor prior to ensure that welding data is associated with theproper registration number 293.

FIG. 23 is an embodiment of a method 389 for weld training usingaugmented reality. A welding operator may select a mode of the weldingsoftware 244 (block 390). The welding software 244 determines whetherthe augmented reality mode 252 has been selected (block 392). If theaugmented reality mode 252 has been selected, the welding software 244executes an augmented reality simulation. It should be noted that thewelding operator may be wearing a welding helmet and/or some otherheadgear configured to position a display device in front of the weldingoperator's view. Furthermore, the display device may generally betransparent to enable the welding operator to view actual objects;however, a virtual welding environment may be portrayed on portions ofthe display device. As part of this augmented reality simulation, thewelding software 244 receives a position and/or an orientation of thewelding torch 14, such as from the sensing device 16 (block 394). Thewelding software 244 integrates the virtual welding environment with theposition and/or the orientation of the welding torch 14 (block 396).Moreover, the welding software 244 provides the integrated virtualwelding environment to the display device (block 398). For example, thewelding software 244 may determine where a weld bead should bepositioned within the welding operator's field of view, and the weldingsoftware 244 may display the weld bead on the display device such thatthe weld bead appears to be on a workpiece. After completion of theweld, the augmented reality simulation may enable the welding operatorto erase a portion of the virtual welding environment (e.g., the weldbead) (block 400), and the welding software 244 returns to block 390.

If the augmented realty mode 252 has not been selected, the weldingsoftware 244 determines whether the live-arc mode 246 has been selected(block 402). If the live-arc mode 246 has been selected, the weldingsoftware 244 enters the live-arc mode 246 and the welding operator mayperform the live-arc weld (block 404). If the live-arc mode 246 has notbeen selected and/or after executing block 404, the welding software 244returns to block 390. Accordingly, the welding software 244 isconfigured to enable a welding operator to practice a weld in theaugmented reality mode 252, to erase at least a portion of the virtualwelding environment from the practice weld, and to perform a live weldin the live-arc mode 246. In certain embodiments, the welding operatormay practice the weld in the augmented reality mode 252 consecutively amultiple number of times.

FIG. 24 is an embodiment of another method 406 for weld training usingaugmented reality. A welding operator may select a mode of the weldingsoftware 244 (block 408). The welding software 244 determines whetherthe augmented reality mode 252 has been selected (block 410). If theaugmented reality mode 252 has been selected, the welding software 244executes an augmented reality simulation. It should be noted that thewelding operator may be wearing a welding helmet and/or some otherheadgear configured to position a display device in front of the weldingoperator's view. Furthermore, the display device may completely blockthe welding operator's field of vision such that images observed by thewelding operator have been captured by a camera and displayed on thedisplay device. As part of this augmented reality simulation, thewelding software 244 receives an image of the welding torch 14, such asfrom the sensing device 16 (block 412). The welding software 244integrates the virtual welding environment with the image of the weldingtorch 14 (block 414). Moreover, the welding software 244 provides theintegrated virtual welding environment with the image of the weldingtorch 14 to the display device (block 416). For example, the weldingsoftware 244 may determine where a weld bead should be positioned withinthe welding operator's field of view and the welding software 244displays the weld bead on the display device with the image of thewelding torch 14 and other objects in the welding environment. Aftercompletion of the weld, the augmented reality simulation may enable thewelding operator to erase a portion of the virtual welding environment(e.g., the weld bead) (block 418), and the welding software 244 returnsto block 408.

If the augmented realty mode 252 has not been selected, the weldingsoftware 244 determines whether the live-arc mode 246 has been selected(block 420). If the live-arc mode 246 has been selected, the weldingsoftware 244 enters the live-arc mode 246 and the welding operator mayperform the live-arc weld (block 422). If the live-arc mode 246 has notbeen selected and/or after executing block 422, the welding software 244returns to block 408. Accordingly, the welding software 244 isconfigured to enable a welding operator to practice a weld in theaugmented reality mode 252, to erase at least a portion of the virtualwelding environment from the practice weld, and to perform a live weldin the live-arc mode 246. In certain embodiments, the welding operatormay practice the weld in the augmented reality mode 252 consecutively amultiple number of times.

FIG. 25 is a block diagram of an embodiment of the welding torch 14. Thewelding torch 14 includes the control circuitry 52, the user interface60, and the display 62 described previously. Furthermore, the weldingtorch 14 includes a variety of sensors and other devices. The weldingtorch 14 may include a temperature sensor 424 (e.g., thermocouple,thermistor, etc.), an inertial sensor 426 (e.g., accelerometer,gyroscope, magnetometer, etc.), a vibration device 428 (e.g., vibrationmotor), a microphone 429, one or more visual indicators 61 (e.g., LEDs64), or any combination thereof. In addition, in certain embodiments,the welding torch 14 may include a voltage sensor 425 and/or a currentsensor 427 to sense voltage and/or current, respectively, of the arcproduced by the welding torch 14. As discussed in detail below, one ormore sets of LEDs 64 may be arranged about the welding torch 14 toenable the sensing device 16 to detect the position and orientation ofthe welding torch 14 relative to the training stand 12 and the workpiece82. For example, sets of LEDs 64 may be arranged on a top side, a leftside, and a right side of the welding torch 14 to enable the sensingdevice 16 to detect the position and orientation of the welding torch 14regardless of which side of the welding torch 14 is facing the sensingdevice 16. In certain embodiments, the welding torch 14 may include morethan one temperature sensor 424, inertial sensor 426, vibration device428, voltage sensor 425, current sensor 427, and/or microphone 429.

During operation, the welding torch 14 may be configured to use thetemperature sensor 424 to detect a temperature associated with thewelding torch 14 (e.g., a temperature of electronic components of thewelding torch 14, a temperature of the display 62, a temperature of alight-emitting device, a temperature of the vibration device, atemperature of a body portion of the welding torch 14, etc.). Thecontrol circuitry 52 (or control circuitry of another device) may usethe detected temperature to perform various events. For example, thecontrol circuitry 52 may be configured to disable use of the live-arcmode 246 (e.g., live welding) by the welding torch 14 if the detectedtemperature reaches and/or surpasses a predetermined threshold (e.g.,such as 85° C.). Moreover, the control circuitry 52 may also beconfigured to disable various heat producing devices of the weldingtorch 14, such as the vibration device 428, light-emitting devices, andso forth. The control circuitry 52 may also be configured to show amessage on the display 62, such as “Waiting for torch to cool down.Sorry for the inconvenience.” In certain embodiments, the controlcircuitry 52 may be configured to disable certain components or featuresif the detected temperature reaches a first threshold and to disableadditional components or features if the detected temperature reaches asecond threshold.

Moreover, during operation, the welding torch 14 may be configured touse the inertial sensor 426 to detect a motion (e.g., acceleration,etc.) associated with the welding torch 14. The control circuitry 52 (orcontrol circuitry of another device) may use the detected accelerationto perform various events. For example, the control circuitry 52 may beconfigured to activate the display 62 (or another display) after theinertial sensor 426 detects that the welding torch 14 has been moved.Accordingly, the control circuitry 52 may direct the display 62 to “wakeup,” such as from a sleep mode and/or to exit a screen saver mode tofacilitate a welding operator of the welding torch 14 using a graphicaluser interface (GUI) on the display 62. Furthermore, the controlcircuitry 52 may utilize feedback from the one or more inertial sensors426 to determine the position of the welding torch 14 in the weldingenvironment and/or the movement of the welding torch 14 within thewelding environment. As discussed in detail below, the sensing devices16 (e.g., camera) may utilize markers 474 on the torch to determine theposition, orientation, and/or movement of the welding torch 14 in thewelding environment. In some embodiments, the control circuitry 52 (orcontrol circuitry of another device) may utilize the feedback from theone or more inertial sensors 426 to augment the determination with thesensing devices 16 of the position, orientation, and/or movement of thewelding torch 14. That is, the control circuitry 52 may determine theposition and orientation of the welding torch 14 based on the feedbackfrom the one or more inertial sensors 426 when the workpiece 82 or theoperator obscures (e.g., blocks) one or more markers 474 of the weldingtorch 14 from the view of the sensing device 16.

Returning to FIG. 21 for an example, the one or more inertial sensors426 may enable the control circuitry 52 to determine the work angle 328,the travel angle 330, and the travel speed 334 for an interval betweentimes 360 and 362 when other sensing devices 16 may be unable to monitorthe position and orientation of the welding torch 14 for any reason(e.g., one or more markers of a set utilized to optically track thewelding torch 14 is obscured from a camera). The one or more inertialsensors 426 may provide an output regarding the position and/or theorientation of the welding torch 14 that is independent of anotherposition detection system (e.g., optical detection system, magneticdetection system, acoustic detection system). The control circuitry 52may determine the work angle 328, the travel angle 330, and the travelspeed 334 based at least in part on the feedback from the one or moreinertial sensors 426 of the welding torch 14 with the assumption thatthe CTWD 332 and the aim of the welding torch 14 relative to the jointof the workpiece 82 are approximately constant for the interval.

Returning to FIG. 25, in certain embodiments, the control circuitry 52may be configured to determine that a high impact event (e.g., dropped,used as a hammer, etc.) to the welding torch 14 has occurred based atleast partly on the detected motion. Upon determining that a high impactevent has occurred, the control circuitry 52 may store (e.g., log) anindication that the welding torch 14 has been impacted. Along with theindication, the control circuitry 52 may store other corresponding data,such as a date, a time of day, an acceleration, a user name, weldingtorch identification data, and so forth. The control circuitry 52 mayalso be configured to show a notice on the display 62 to a weldingoperator requesting that the operator refrain from impacting the weldingtorch 14. In some embodiments, the control circuitry 52 may beconfigured to use the motion detected by the inertial sensor 426 toenable the welding operator to navigate and/or make selections within asoftware user interface (e.g., welding software, welding trainingsoftware, etc.). For example, the control circuitry 52 may be configuredto receive the acceleration and to make a software selection if theacceleration matches a predetermined pattern (e.g., the accelerationindicates a jerky motion in a certain direction, the accelerationindicates that the welding torch 14 is being shaken, etc.).

The vibration device 428 is configured to provide feedback to a weldingoperator by directing the welding torch 14 to vibrate and/or shake(e.g., providing vibration or haptic feedback). The vibration device 428may provide vibration feedback during live welding and/or duringsimulated welding. As may be appreciated, vibration feedback during livewelding may be tuned to a specific frequency to enable a weldingoperator to differentiate between vibration that occurs due to livewelding and the vibration feedback. For example, vibration feedback maybe provided at approximately 3.5 Hz during live welding. Using such afrequency may enable a welding operator to detect when vibrationfeedback is occurring at the same time that natural vibration occur dueto live welding. Conversely, vibration feedback may be provided atapproximately 9 Hz during live welding. However, the 9 Hz frequency maybe confused with natural vibration that occurs due to live welding.

The one or more microphones 429 are configured to facilitatedetermination of the position of the welding torch 14 with a localpositioning system. The one or more microphones 429 of the welding torch14 receive emitted signals (e.g., ultrasonic, RF) from beacons disposedat known locations about the welding environment. As may be appreciated,a local positioning system enables the determination of a location of anobject when the object receives the emitted signals (i.e., viaunobstructed line of sight) from three or more beacons at knownpositions. The control circuitry 52 (or control circuitry of anotherdevice) may determine the position of the welding torch 14 from thereceived signals via triangulation, trilateration, or multilateration.In some embodiments, the microphones 429 may facilitate thedetermination of the position of the welding torch 14 during weldingwhen one or more of the sensing devices 16 (e.g., cameras) areobstructed by the workpiece 82 and/or the operator.

FIG. 26 is an embodiment of a method 430 for providing vibrationfeedback to a welding operator using the welding torch 14. The controlcircuitry 52 (or control circuitry of another device) detects aparameter (e.g., work angle, travel angle, travel speed, tip-to-workdistance, aim, etc.) corresponding to a welding operation (block 432).As may be appreciated, the welding operation may be a live weldingoperation, a simulated welding operation, a virtual reality weldingoperation, and/or an augmented reality welding operation. The controlcircuitry 52 determines whether the parameter is within a firstpredetermined range (block 434). As may be appreciated, the firstpredetermined range may be a range that is just outside of an acceptablerange. For example, the parameter may be work angle, the acceptablerange may be 45 to 50 degrees, and the first predetermined range may be50 to 55 degrees. Accordingly, in such an example, the control circuitry52 determines whether the work angle is within the first predeterminedrange of 50 to 55 degrees.

If the parameter is within the first predetermined range, the controlcircuitry 52 vibrates the welding torch at a first pattern (block 436).The first pattern may be a first frequency, a first frequencymodulation, a first amplitude, and so forth. Moreover, if the parameteris not within the first predetermined range, the control circuitry 52determines whether the parameter is within a second predetermined range(block 438). The second predetermined range may be a range that is justoutside of the first predetermined range. For example, continuing theexample discussed above, the second predetermined range may be 55 to 60degrees. Accordingly, in such an example, the control circuitry 52determines whether the work angle is within the second predeterminedrange of 55 to 60 degrees. If the parameter is within the secondpredetermined range, the control circuitry 52 vibrates the welding torchat a second pattern (block 440). The second pattern may be a secondfrequency, a second frequency modulation, a second amplitude, and soforth. It should be noted that the second pattern is typically differentthan the first pattern. In certain embodiments, the first and secondpatterns may be the same. Furthermore, audible indications may beprovided to the welding operator to indicate whether the parameter iswithin the first predetermined range or within the second predeterminedrange. In addition, audible indications may be used to indicate aparameter that is not within an acceptable range. In such embodiments,vibration may be used to indicate that a welding operator is doingsomething wrong, and audible indications may be used to identify whatthe welding operator is doing wrong and/or how to fix it. The parametermay be any suitable parameter, such as a work angle, a travel angle, atravel speed, a tip-to-work distance, and/or an aim. FIGS. 27 through 29illustrate embodiments of various patterns.

FIG. 27 is a graph 442 of an embodiment of two patterns each including adifferent frequency for providing vibration feedback to a weldingoperator. A first pattern 444 is separated from a second pattern 446 bytime 448. In the illustrated embodiment, the first pattern 444 is afirst frequency and the second pattern 446 is a second frequency that isdifferent from the first frequency. The first and second frequencies maybe any suitable frequency. As may be appreciated, the first and secondfrequencies may be configured to be different than a natural frequencyproduced during live welding to facilitate a welding operatordifferentiating between the natural frequency and the first and secondfrequencies. Although the illustrated embodiment shows the firstfrequency being lower than the second frequency, in other embodiments,the second frequency may be lower than the first frequency.

FIG. 28 is a graph 450 of an embodiment of two patterns each including adifferent modulation for providing vibration feedback to a weldingoperator. A first pattern 452 is separated from a second pattern 454 bytime 456. In the illustrated embodiment, the first pattern 452 is afirst modulation and the second pattern 454 is a second modulation thatis different from the first modulation. The first and second modulationmay be any suitable modulation. For example, the first modulation mayinclude a first number of vibration pulses (e.g., two pulses) and thesecond modulation may include a second number of vibration pulses (e.g.,three pulses). Moreover, the modulation may vary a number of pulses, atime between pulses, etc. In certain embodiments, a number of vibrationpulses and/or a time between pulses may be configured to graduallyincrease or decrease as a parameter moves toward or away from acceptableparameter values. Although the illustrated embodiment shows the firstmodulation as having fewer pulses than the second modulation, in otherembodiments, the second modulation may have fewer pulses than the firstmodulation.

FIG. 29 is a graph 458 of an embodiment of two patterns each including adifferent amplitude for providing vibration feedback to a weldingoperator. A first pattern 460 is separated from a second pattern 462 bytime 464. In the illustrated embodiment, the first pattern 460 is afirst amplitude and the second pattern 462 is a second amplitude that isdifferent from the first amplitude. The first and second amplitudes maybe any suitable amplitude. Although the illustrated embodiment shows thefirst amplitude being lower than the second amplitude, in otherembodiments, the second amplitude may be lower than the first amplitude.

The welding torch 14 may provide varied levels of vibration and visualfeedback to the operator during simulated welding or live welding. Forexample, a first feedback mode of the welding torch 14 may providevisual feedback (e.g., via display 62) and vibration feedback to theoperator until the operator initiates a simulated or live weldingprocess, and the welding torch 14 may not provide visual or vibrationfeedback during the simulated or live welding process. A second feedbackmode of the welding torch 14 may provide visual and vibration feedbackto the operator both prior to and during the simulated or live weldingprocess. A third feedback mode of the welding torch may provide visualand vibration feedback to the operator both prior to and during onlysimulated welding processes. As may be appreciated, some modes mayprovide only visual feedback prior to or during a simulated weldingprocess, and other modes may provide only vibration feedback prior to orduring a simulated welding process. In some embodiments, an instructormay specify the level of feedback that may be provided to the operatorduring simulated or live welding sessions to be evaluated. Moreover, theoperator may selectively disable vibration and/or visual feedbackprovided by the welding torch prior to and during simulated or livewelding.

FIG. 30 is a perspective view of an embodiment of the welding torch 14having markers that may be used for tracking the welding torch 14. WhileFIGS. 30 and 31 illustrate a welding torch 14, other welding devices(e.g., welding tools, stingers, calibration tools) may have markers 474(e.g., visual markers 802) arranged about the respective welding devicein a prescribed pattern that corresponds to a rigid body model of thewelding device. Accordingly, from a set of markers 474 detected by thesensing device 16, the computer 18 coupled to the sensing device 16 maydetermine the type of welding device, a rigid body model for the weldingdevice, a position of the welding device, and an orientation of thewelding device. In some embodiments, the position of the welding torch14 may be tracked prior to live welding to determine (i.e., calibrate)the shape of the welding joint. For example, the welding torch 14 may beutilized to trace the shape of a workpiece 82 in various positionsincluding, but not limited, to welding positions 1G, 2G, 3G, 4G, 5G, 6G,1F, 2F, 3F, 4F, 5F, or 6F. The determined shape of the welding joint maybe stored in the data storage system 318 for comparison with asubsequent live welding process along the welding joint. In someembodiments, the position of the welding torch 14 may be tracked duringlive welding and compared with the shape of the welding joint stored inthe data storage system 318. The control circuitry 52 of the weldingtorch 14 and/or any other component of the training system 10 mayprovide approximately real-time feedback to the operator regarding theposition (e.g., location) and/or orientation of the welding torch 14relative to the welding joint. The welding torch 14 includes a housing466 that encloses the control circuitry 52 of the welding torch 14and/or any other components of the welding torch 14. The display 62 anduser interface 60 are incorporated into a top portion of the housing466.

As illustrated, a neck 470 extends from the housing 466 of the weldingtorch 14. Markers for tracking the welding torch 14 may be disposed onthe neck 470. Specifically, a mounting bar 472 is used to couple markers474 to the neck 470. The markers 474 are spherical markers in theillustrated embodiment; however, in other embodiments, the markers 474may be any suitable shape (e.g., such as a shape of an LED). The markers474 are used by the sensing device 16 for tracking the position and/orthe orientation of the welding torch 14. As may be appreciated, three ofthe markers 474 are used to define a first plane. Moreover, the markers474 are arranged such that a fourth marker 474 is in a second planedifferent than the first plane. Accordingly, the sensing device 16 maybe used to track the position and/or the orientation of the weldingtorch 14 using the four markers 474. It should be noted that while theillustrated embodiment shows four markers 474, the mounting bar 472 mayhave any suitable number of markers 474.

In certain embodiments, the markers 474 may be reflective markers (e.g.,retroreflectors), while in other embodiments the markers 474 may belight-emitting markers (e.g., light-emitting diodes LEDs 64). Inembodiments in which the markers 474 are light-emitting markers, themarkers 474 may be powered by electrical components within the housing466 of the welding torch 14. For example, the markers 474 may be poweredby a connection 476 between the mounting bar 472 and the housing 466.Furthermore, the control circuitry 52 (or control circuitry of anotherdevice) may be used to control powering on and/or off (e.g.,illuminating) the markers 474. In certain embodiments, the markers 474may be individually powered on and/or off based on the position and/orthe orientation of the welding torch 14. In other embodiments, themarkers 474 may be powered on and/or off in groups based on the positionand/or the orientation of the welding torch 14. It should be noted thatin embodiments that do not include the mounting bar 472, the connection476 may be replaced with another marker 468 on a separate plane than theillustrated markers 468. Embodiments of the welding torch 14 aredescribed herein relative to a consistent set of coordinate axes 780. AnX-axis 782 is a horizontal direction along a longitudinal axis of thewelding torch 14, a Y-axis 784 is the vertical direction relative to thelongitudinal axis, and a Z-axis 786 is a horizontal direction extendinglaterally from the welding torch 14.

FIG. 31 is an embodiment of a neck 800 of the welding torch 14, takenalong line 31-31 of FIG. 30. Visual markers 802 are arranged atpredefined locations on the neck 800 to facilitate detection of theposition and orientation of the welding torch 14 by the sensing device16. In some embodiments, the visual markers 802 are LEDs 64.Additionally, or in the alternative, the visual markers 802 aredirectional, such that the sensing device 16 detects visual markers 802that are oriented (e.g., centered) toward the sensing device 16 (e.g.,one or more cameras) more readily than visual markers 802 that are lessoriented toward the sensing device 16. For example, LEDs 64 arranged ona surface may be directed to emit light (e.g., visible light, infraredlight, ultraviolet light) primarily along an axis substantiallyperpendicular to the surface. Furthermore, one or more of the visualmarkers 802 may be retroreflectors configured to reflect lightsubstantially toward the direction from which the respective visualmarker received the light (e.g., from an infrared light positioned neara camera sensing device 16). In some embodiments, multiple sets ofvisual markers 802 are arranged on the neck 800.

The visual markers 802 of each set may be oriented (e.g., centered) insubstantially the same direction as the other visual markers 802 of therespective set. In some embodiments, a first set 804 of visual markers802 is directed substantially vertically along the Y-axis 784, a secondset 806 of visual markers 802 is directed in a second direction 808, anda third set 810 of visual markers 802 is directed in a third direction812. That is, the visual markers 802 of each set are oriented to emitlight in substantially parallel directions as other visual markers 802of the respective set. The second direction 808 is substantiallyperpendicular to the X-axis 782 along the welding torch 14, and isoffset a second angle 814 from the Y-axis 784. The third direction 812is substantially perpendicular to the X-axis 782 along the welding torch14, and is offset a third angle 816 from the Y-axis 784. In someembodiments, the second angle 814 and the third angle 816 haveapproximately the same magnitude. For example, the second set 806 ofvisual indicators 802 may be offset from the Y-axis 784 by 45°, and thethird set 810 of visual indicators 802 may be offset from the Y-axis 784by 45°, such that the second angle 814 is substantially perpendicularwith the third angle 816. The second angle 814 and the third angle 816may each be between approximately 5° to 180°, 15° to 135°, 25° to 90°,or 30° to 75°. As may be appreciated, the neck 800 may have 1, 2, 3, 4,5, 6, 7, 8, 9, 10, or more sets of visual markers 802, with each setoriented in a particular direction to facilitate detection by thesensing device 16.

The visual markers 802 of each set may be arranged on the same orsubstantially parallel planes. For example, the first set 804 of visualmarkers 802 may be arranged on a first plane 818 or a planesubstantially parallel to the first plane 818 that is perpendicular tothe Y-axis 784. The second set 806 of visual markers 802 may be arrangedon a second plane 820 or a plane substantially parallel to the secondplane 820 that is perpendicular to the second direction 808. The thirdset 810 of visual markers 802 may be arranged on a third plane 822 or aplane substantially parallel to the third plane 822 that isperpendicular to the third direction 812. In some embodiments, thevisual markers 802 of each set may be spatially distributed about thewelding torch 14 to maximize the distance between the visual markers 802of the respective set, which may facilitate determination of theposition and orientation of the welding torch 14 relative to the sensingdevice relative to a more narrow spatial distribution. As used herein,the term “substantially parallel” includes orientations within 10degrees of parallel, and the term “substantially perpendicular” includesorientations within 10 degrees of perpendicular. The arrangements of thevisual markers 802 of each set may facilitate tracking the welding torch14 during simulated and/or live out of position welding processesincluding, but not limited to, vertical or overhead welding positions.

Structures 824 of the neck 800 may facilitate the orientation of thesets of the visual markers 802. For example, a mounting surface of eachstructure 824 may be substantially parallel to a respective plane forthe corresponding set of visual markers 802. Moreover, the structures824 may reduce or eliminate the detection of the respective visualmarker 802 by the sensing device 16 when the respective visual marker802 is oriented relative to the sensing device 16 at an angle greaterthan a threshold angle. For example, the second set 806 of visualmarkers 802 may be configured to be detected by the sensing device 16when the operator holds the welding torch 14 with the sensing device 16to the left of the operator (i.e., a left-handed operator), and thethird set 810 of visual markers 802 may be configured to be detected bythe sensing device 16 when the operator holds the welding torch 14 withthe sensing device 16 to the right of the operator (i.e., a right-handedoperator). The neck 800 and/or the structures 824 for the second set 806of visual markers 802 may reduce or eliminate the detection of thesecond set 806 of visual markers 802 when a right-handed operator usesthe welding torch 14, and vice versa for the third set 810 of visualmarkers when a left-handed operator uses the welding torch 14.

FIG. 32 is a top view of an arrangement of visual markers 80 on the neck800 of the welding torch 14, similar to the embodiment of the neck 800illustrated in FIG. 31. The visual markers 802 of the first set 804(e.g., “A”), the second set 806 (e.g., “B”), and the third set 810(e.g., “C”) are arranged at different predefined positions on the neck800 that enable the sensing device 16 to determine which side of thewelding torch 14 is most directed towards the sensing device 16 viadetecting a distinct pattern or arrangement that corresponds to eachside (e.g., top, left 826, right 828, bottom, front) of the weldingtorch 14. Additionally, or in the alternative, the visual markers 802(e.g., LEDs 64) of each set may be respectively colored, therebyenabling the sensing device 16 to determine which side of the weldingtorch 14 is most directed towards the sensing device 16 via colordetection. That is, the first set 804 may emit light within a firstspectrum (e.g., approximately 730 nm infrared), the second set 806 mayemit light within a second spectrum (e.g., approximately 850 nminfrared), and the third set 810 may emit light within a third spectrum(e.g., approximately 940 nm). Different wavelengths for each set ofvisual markers 802 may enable the controller (e.g., computer 18) coupledto the sensing device 16 to readily determine which set of visualmarkers 802 and which side of the welding torch 14 are visible to thesensing device 16 based at least in part on which wavelengths aredetected.

The sensing device 16 may track the position and orientation of thewelding torch 14 relative to the training stand 12 and the workpiece 82when the sensing device 16 detects a threshold quantity of visualmarkers 802 of a set. The threshold quantity of visual markers 802 of aset may be at least three, four, five, or more visual markers 802detectable by the sensing device 16 at a time. The threshold quantity ofvisual markers 802 of a set may be less than or equal to the quantity ofvisual markers 802 of the respective set. For example, the sensingdevice 16 may detect the right side of the welding torch 14 whendetecting the four visual markers 802 of the third set 810, the sensingdevice 16 may detect the top side of the welding torch 14 when detectingthe five visual markers 802 of the first set 804, and the sensing device16 may detect the left side of the welding torch when detecting the fourvisual markers 802 of the second set. In some embodiments, each set ofvisual markers 802 may have redundant visual markers, such that sensingdevice 16 may track the position and the orientation of the weldingtorch 14 when one or more of the redundant visual markers are obscuredfrom view. The sensing device 16 may track the position and theorientation with substantially the same accuracy, regardless of whichset is detected by the sensing device 16. In some embodiments, thethreshold quantity of visual markers 802 of a respective set

The visual markers 802 may be arranged on the neck 800 of the weldingtorch 14 at positions relative to the X-axis 782 along the welding torch14, and relative to a baseline 830. For example, the first set 804 mayhave five visual markers 802: two visual markers 802 along the baseline830 near a first end 832 of the neck 800 and spaced a first offset 831from the X-axis 782, a visual marker 802 spaced a first distance 834from the baseline 830 in a midsection 836 of the neck 800 and spaced asecond offset 838 from the X-axis 782 to the left side 826, a visualmarker 802 spaced a third distance 840 from the baseline 830 in themidsection 836 and spaced the second offset 838 to the right side 828,and a visual marker 802 near a second end 842 of the neck 800 along theX-axis 782 and spaced a fourth distance 844 from the baseline 830. Thesecond set 806 may have four visual markers 802: a visual marker 802along the baseline 830 and spaced a third offset 846 from the X-axis 782on the left side 826, a visual marker 802 spaced a fifth distance 848from the baseline 830 along the X-axis 782 in the midsection 836, avisual marker 802 spaced a sixth distance 850 from the baseline 830 inthe midsection 836 and spaced the second offset 838 from the X-axis 782on the right side 828, and a visual marker 802 near the second end 842of the neck 800 spaced the fourth distance 844 from the baseline 830 andspaced the second offset 838 on the left side 826. The third set 810 mayhave four visual markers 802: a visual marker 802 along the baseline 830and spaced the third offset 846 from the X-axis 782 on the right side828, a visual marker 802 spaced a seventh distance 852 from baseline 830along the X-axis 782 in the midsection 836, a visual marker 802 spacedan eighth distance 854 from the baseline 830 in the midsection 836 andspaced the second offset 838 from the X-axis 782 on the left side 826,and a visual marker 802 near the second end 842 of the neck 800 spacedthe fourth distance 844 from the baseline 830 and spaced the secondoffset 838 on the right side 828.

The arrangements (e.g., distances and offsets relative to the baseline830 and X-axis 782) of the visual markers 802 for each set 804, 806, 810may be stored in a memory of the welding system 10. For example, thearrangements may be stored in a memory as calibrations corresponding toa particular welding torch coupled to the welding system 10. Asdiscussed in detail below, the welding system 10 may detect thearrangement of the visual markers 802 directed to the sensing device 16,and determine the position and orientation of the welding torch 14relative to the training stand 12 and the workpiece 82 based at least inpart on a comparison of the detected arrangement and the arrangementsstored in memory. Each set of visual markers 802 may be calibrated, suchas prior to an initial use, after reconnecting the welding torch 14, orat a predetermined maintenance interval. To calibrate a set of visualmarkers 802, the welding torch 14 may be mounted to the training stand12 in a predetermined position and orientation such that the respectiveset of visual markers 802 is substantially directed toward the sensingdevice 16. For example, the first set 804 may be calibrated when thewelding torch 14 is mounted such that the Y-axis 784 of the weldingtorch 14 is generally directed toward the sensing device 16, the secondset 806 may be calibrated when the welding torch 14 is mounted such thatthe second direction 808 is generally directed toward the sensing device16, and the third set 810 may be calibrated when the welding torch 14 ismounted such that the third direction 812 is generally directed towardthe sensing device 16. In some embodiments, the sets of visual markers802 are calibrated when a calibration tool (e.g., calibration tool 610discussed below) is coupled to the welding torch 14. The operator mayverify the calibrations by moving the welding torch 14 about the weldingenvironment relative to the training stand 12 and the sensing device 16.

FIG. 33 is an embodiment of a method 478 for displaying on a display ofa welding torch a welding parameter in relation to a threshold. In theillustrated embodiment, the control circuitry 52 (or control circuitryof another device) receives a selection made by a welding operator of awelding parameter associated with a position, an orientation, and/or amovement of the welding torch 14 (block 480). For example, the weldingoperator may select a button on the user interface 60 of the weldingtorch 14 to select a welding parameter. The welding parameter may be anysuitable welding parameter, such as a work angle, a travel angle, atravel speed, a tip-to-work distance, an aim, and so forth. As may beappreciated, the welding system 10 may select the welding parameterautomatically without input from a welding operator. After the selectionis made, the display 62 of the welding torch 14 displays or shows arepresentation of the welding parameter in relation to a predeterminedthreshold range and/or target value for the welding parameter (block482). The displayed welding parameter is configured to change as theposition of the welding torch 14 changes, as the orientation of thewelding torch 14 changes, and/or as movement of the welding torch 14changes. Thus, the welding operator may use the welding torch 14 toproperly position and/or orient the welding torch 14 while performing(e.g., prior to beginning, starting, stopping, etc.) a weldingoperation, thereby enabling the welding operator to perform the weldingoperation with the welding parameter within the predetermined thresholdrange or at the target value.

For example, the welding operator may desire to begin the weldingoperation with a proper work angle. Accordingly, the welding operatormay select “work angle” on the welding torch 14. After “work angle” isselected, the welding operator may position the welding torch 14 at adesired work angle. As the welding operator moves the welding torch 14,a current work angle is displayed in relation to a desired work angle.Thus, the welding operator may move the welding torch 14 around untilthe current work angle matches the desired work angle and/or is within adesired range of work angles. As may be appreciated, the display 62 maybe turned off and/or darkened so that it is blank during a weldingoperation. However, a welding operator may select a desired weldingparameter prior to performing the welding operation. Even with thedisplay 62 blank, the control circuitry 52 may be configured to monitorthe welding parameter and provide feedback to the welding operatorduring the welding operation (e.g., vibration feedback, audio feedback,etc.).

FIG. 34 is an embodiment of a set of screenshots of the display 62 ofthe welding torch 14 for showing a welding parameter in relation to athreshold. The set of screenshots illustrate various ways that weldingparameters are displayed for a welding operator for performing a weldingoperation. As may be appreciated, in certain embodiments, the weldingparameters may be displayed to the welding operator before, during,and/or after the welding operation. Screen 484 illustrates a work anglethat is not within a predetermined threshold range. A parameter portion486 of the display 62 indicates the selected parameter. Moreover, arange section 488 indicates whether the selected parameter is within thepredetermined threshold range. Furthermore, a parameter value section490 indicates the value of the selected parameter. On the screen 484,the work angle of 38 is out of range as indicated by the arrow extendingoutward from the central circle. Screen 492 illustrates a work angle of45 that is within the predetermined threshold range as indicated by noarrow extending from the central circle.

As may be appreciated, the sensing device 16 may be configured to detectwhether the travel angle is a drag angle (e.g., the travel angle isahead of the welding arc) or a push angle (e.g., the travel anglefollows behind the welding arc). Accordingly, screen 494 illustrates adrag travel angle of 23 that is outside of a predetermined thresholdrange as indicated by an arrow extending outward from a central circle.Conversely, screen 496 illustrates a push travel angle of 15 that iswithin the predetermined threshold range as indicated by no arrowextending from the central circle. Furthermore, screen 498 illustrates atravel speed of 12 that is within of a predetermined threshold range asindicated by a vertical line aligned with the central circle.Conversely, screen 500 illustrates a travel speed of the welding torch14 that is outside of (i.e., greater than) the predetermined thresholdrange as indicated by the vertical line to the right of the centralcircle. As may be appreciated, a travel speed that is less than apredetermined threshold range may be indicated by a vertical line to theleft of the central circle. The travel speed indicator may dynamicallymove relative to the central circle in real-time during a weld processbased at least in part on the determined travel speed, thereby guidingthe operator to perform the weld process with a travel speed within thepredetermined threshold range.

Screen 502 illustrates a tip-to-work distance of 1.5 that is greaterthan a predetermined threshold range as indicated by a small circlewithin an outer band. Moreover, screen 504 illustrates the tip-to-workdistance of 0.4 that is less than a predetermined threshold range asindicated by the circle outside of the outer band. Furthermore, screen506 illustrates the tip-to-work distance of 1.1 that is within thepredetermined threshold range as indicated by the circle substantiallyfilling the area within the outer band. Moreover, screen 508 illustratesan aim of 0.02 that is within a predetermined threshold range asindicated by a line 509 aligned with a central circle. Conversely,screen 510 illustrates an aim of 0.08 that is not within thepredetermined threshold range as indicated by the line 509 toward thetop part of the central circle. In some embodiments, the line 509 ofscreens 508 and 510 represents the joint relative to the tip of thewelding torch 14. For example, screens 508 and 510 illustrate the aim ofthe welding torch 14 when the welding torch 14 is oriented substantiallyperpendicular to the joint (as illustrated by the line 509).

Screen 511 illustrates the aim of the welding torch 14 when the weldingtorch 14 is at least partially angled relative to the joint, asindicated by the line 509 and the tilted orientation of the weldingtorch 14. That is, while the positions of the welding torch 14 relativeto the joint (e.g., line 509) corresponding to screens 508 and 511 aresubstantially the same, the orientation of the line 509 of screen 508 onthe display corresponds to a perpendicular orientation of the weldingtorch 14 relative to the joint and the orientation of the line 509 ofscreen 511 on the display 62 corresponds to a non-perpendicularorientation of the welding torch 14 relative to the joint. Theorientation of the range section 488 (e.g., aim indicator, angleindicator, CTWD indicator) may be rotated on the display by a rotationangle defined as the angle difference between a front edge 513 of thedisplay 62 and the joint. The graphical representations on the display62 may correspond to the orientation of the welding torch 14 relative tothe joint rather than to the orientation of the display 62 relative tothe operator. For example, when the welding torch 14 is positioned neara vertical joint such that the welding torch 14 is substantiallyparallel with the joint, the line 509 on the display 62 may be orientedvertically on the display 62. The joint indicator line 509 may besubstantially perpendicular to the travel speed indicator discussedabove with screens 498 and 500. The graphical representations on thedisplay 62 may be rotated on the display 62 to correspond to theorientation of the welding torch 14 relative to the joint based at leastin part on the determined orientation of the welding torch 14 based onthe detected visual markers 802 (e.g., LEDs 64), feedback from theinertial sensors 426 of the welding torch 14, or any combinationthereof. In some embodiments, a default mode of the display 62 of thewelding torch 14 is to display the graphical representations as shown inscreens 484, 492, 494, 496, 498, 500, 502, 504, 506, 508, and 510, wherethe welding torch 14 is moved substantially horizontally (e.g.,right-to-left, left-to-right) during the welding operation. The display62 may be configured in a rotation mode that enables rotation of thegraphical representations on the display 62, as illustrated in screen511. Rotation of the graphical representations on the display 62 mayenable the operator perception that the graphical representation“floats” as the welding torch 14 and the housing 466 about the display62 move or rotate relative to the joint. That is, the arrangement of thearrows and lines of the graphical representation on the display 62 maynot change relative to the operator viewing the display 62 despite atilted or rotated position of the welding torch 14 relative to thejoint.

While specific graphical representations have been shown on the display62 in the illustrated embodiment for showing a welding parameter inrelation to a threshold, other embodiments may use any suitablegraphical representations for showing a welding parameter in relation toa threshold. Moreover, in certain embodiments individual parametervisual guides may be combined so that multiple parameters are visuallydisplayed together. For example, screen 511 on the display 62 mayillustrate in substantially real-time via the rotated graphicalrepresentation the indicators (e.g., range section 488, arrows, bars)for a work angle that is less than the predetermined threshold workangle range, a push travel angle outside the predetermined thresholdtravel angle range, a tip-to-work distance that is within thepredetermined tip-to-work distance threshold range, an aim that iswithin the predetermined aim threshold range, and a travel speed that isgreater than a predetermined travel speed threshold range. In someembodiments, the operator may adjust the display 62 to display only aselected indicator (e.g., travel speed, travel angle, tip-to-workdistance) in real-time during a live or training welding operation. Insome embodiments, the display 62 may cycle through the variousindicators of welding parameters during the live or training weldingoperation, or the display 62 may illustrate in substantially real-timeonly the one or more indicators for parameters that are outside of therespective threshold ranges.

Furthermore, in certain embodiments, the welding system 10 may detect ifthe welding torch 14 is near and/or far from a welding joint. Being nearthe welding joint is a function of the contact tip-to-work distance(CTWD) and aim parameters. When both the CTWD and aim parameters arewithin suitable predetermined ranges (e.g., less than 3.0, 2.0, 1.5,1.0, or 0.5 inches each), the welding system 10 may consider the weldingtorch 14 near the welding joint. Furthermore, the control circuitry 52of the welding torch 14 or another device may determine the work angle,the travel angle, and the travel speed based at least in part on theposition of the welding torch 14 relative to a known (e.g., calibrated)welding joint of the workpiece 82 when the CTWD and the aim aresubstantially constant along the welding joint. As may be appreciated,the position and orientation of the welding torch 14 may be determinedvia the sensing devices 16 and the markers 474, the one or more inertialsensors 426, and/or the one or more microphones 429 of the welding torch14. In some embodiments, a second position detection system (e.g.,inertial sensor(s) 426 of the welding torch 14, microphone(s) 429 of thewelding torch 14) may only be activated when the welding torch 14 ispositioned near the welding joint. The second position detection systemmay be deactivated when the welding torch 14 is not near the weldingjoint, such that the sensing devices 16 and the markers 474 may beutilized to determine the position and/or orientation of the weldingtorch 14 within the welding environment. Moreover, when the weldingtorch 14 is near the welding joint, the visual guides may be displayedon the welding torch 14. When the welding torch 14 is near the weldingjoint and in the live welding mode, a message (e.g., warning message)may be displayed on a display indicating that proper welding equipment(e.g., welding helmet, etc.) should be in place as a safety precautionfor onlookers. However, an external display may continue to display thereal-time data at a safe distance from the welding operation. Moreover,in some embodiments, when the welding torch 14 is near the welding jointand in the live welding mode, the display of the welding torch 14 may bechanged (e.g., to substantially blank and/or clear, to a non-distractingview, to a predetermined image, etc.) while a welding operator actuatesthe trigger of the welding torch 14. When the welding torch 14 is farfrom the welding joint, actuating the trigger of the welding torch 14will not perform (e.g., begin) a test run. Furthermore, when the weldingtorch 14 is far from the welding joint, actuating the welding torch 14will have no effect in a non-live welding mode, and may feed weldingwire in the live welding mode without beginning a test run.

FIG. 35 is an embodiment of a method 512 for tracking the welding torch14 in the welding system 10 using at least four markers. One or morecameras (e.g., such as one or more cameras of the sensing system 16) areused to detect the markers of the welding torch 14 (block 514). Asdiscussed above, the markers may be reflective markers (e.g.,retroreflectors) and/or light-emitting markers. Furthermore, the markersmay include four or more markers to facilitate determining an accurateposition and/or orientation of the welding torch 14. One or moreprocessors 20 of the computer 18 (or other processors) may be used withthe sensing system 16 to track the position of the welding torch 14and/or the orientation of the welding torch 14 based on the detectedmarkers (block 516). If the one or more cameras are unable to detect oneor more of the markers, the one or more processors 20 (or controlcircuitry, such as the control circuitry 52) may be configured to blocklive welding while the one or more cameras are unable to detect themarkers (block 518). However, in some embodiments of the welding system10, one or more cameras integrated with the helmet 41 may enabledetection of four or more markers to facilitate determining an accurateposition and/or orientation of the welding torch 14 with respect to thewelding helmet 41. Thus, one or more cameras integrated with the helmet41 may facilitate detection of the position and/or orientation of thewelding torch 14 for welding processes that would otherwise obscure theone or more markers from cameras mounted to the stand 12. As may beappreciated, the position and/or orientation of the welding helmet 41 inthe welding environment may be determined via the one or more sensingdevices 16 of the welding system 10 in a similar manner as describedabove for the welding torch 14 where the markers are observable. In someembodiments, the display 62 of the welding torch 14 may be configured todisplay a message indicating that the markers are not detected while theone or more cameras are unable to detect the markers of the weldingtorch 14 (block 520). Accordingly, live welding using the welding torch14 may be blocked if the welding torch 14 is unable to be tracked by thesensing system 16.

Some embodiments of the welding system 10 may track the welding torch 14in the welding environment during periods where one or more of themarkers 474 are obscured and not detected. Some embodiments may utilizeposition detection systems that directly observe a portion of thewelding torch 14 without the markers 474. Furthermore, the weldingsystem 10 may include one or more of various types (e.g., line-of-sightbased (i.e., infrared, visible light, or acoustic), electromagneticradiation based, radio signal based, inertial based) of positiondetection systems that may be used independently or in combination tofacilitate tracking the position, orientation, and/or movement of thewelding torch 14 relative to the workpiece 82. In some embodiments,control circuitry (e.g., computer 18) of the welding system 10 mayindependently store output from each position detection system, therebyfacilitating separate analysis and/or weighting of the respectiveoutputs to determine the position and orientation of the welding torchwithin the welding environment. For example, output from differentposition detection systems may be weighted based on an accuracy of theoutput, a reliability of the output, a calibration of the respectiveposition detection system, or any combination thereof. As describedabove, the welding system 10 may track the position and/or theorientation of the welding torch 14 based at least in part on feedbackfrom one or more inertial sensors 426 (e.g., accelerometers, gyroscopes)of the welding torch 14. Moreover, embodiments of the welding system 10with beacons of a local positioning system and one or more microphones429 on the welding torch 14 may determine a position of the weldingtorch 14 within the welding environment when the portions (e.g., markers474) of the welding torch 14 are obscured from the line of sight of somesensing devices 16 (e.g., cameras). Accordingly, block 518 of method 512(to block live welding while the markers are not detected) may beoptional during intervals when the control circuitry 52 may otherwisedetermine the position of the welding torch 14 within the weldingenvironment. Additionally, or in the alternative, the welding system 10may track the welding torch 14 in the welding environment when thewelding torch 14 does not have markers 474 as described above.Therefore, in some embodiments, the control circuitry 52 permits livewelding while the markers are not detected or not present on the weldingtorch 14.

FIG. 36 is an embodiment of a method 522 for detecting the ability forthe processor 20 (or any other processor) to communicate with thewelding torch 14. The welding torch 14 is configured to detect a signalfrom the processor 20 (block 524). The signal is provided from theprocessor 20 to the welding torch 14 at a predetermined interval. Incertain embodiments, the signal may be a pulsed signal provided from theprocessor 20 to the welding torch 14 at the predetermined interval.Moreover, the signal is provided to the welding torch 14 so that thewelding torch 14 is able to determine that the welding torch 14 is ableto communicate with the processor 20. If the welding torch 14 does notreceive the signal from the processor 20 within the predeterminedinterval, control circuitry 52 (or control circuitry of another device)is configured to block live welding using the welding torch 14 while thesignal is not detected (block 526). Moreover, the display 62 may beconfigured to display a message indicating that the signal from theprocessor 20 is not detected while the live welding is blocked (block528). Accordingly, the welding torch 14 may detect the ability for theprocessor 20 to communicate with the welding torch 14.

FIG. 37 is an embodiment of a method 530 for calibrating a curved weldjoint that may be used with the welding system 10. One or more cameras(e.g., such as one or more cameras of the sensing system 16) are used todetect a first position (e.g., first calibration point) of the curvedweld joint (block 532). For example, a calibration tool and/or thewelding torch 14 may be used to identify the first position of thecurved weld joint to the one or more cameras (e.g., such as by touchinga tip of the calibration tool and/or the welding torch 14 to the firstposition). In addition, the one or more cameras may be used to track thecalibration tool and/or the welding torch 14 to determine a positionand/or an orientation of the calibration tool and/or the welding torch14 for detecting the first position of the curved weld joint.

Moreover, the one or more cameras are used to detect a second position(e.g., second calibration point) of the curved weld joint (block 534).For example, the calibration tool and/or the welding torch 14 may beused to identify the second position of the curved weld joint to the oneor more cameras. In addition, the one or more cameras may be used totrack the calibration tool and/or the welding torch 14 to determine aposition and/or an orientation of the calibration tool and/or thewelding torch 14 for detecting the second position of the curved weldjoint. Furthermore, the one or more cameras are used to detect a curvedportion of the curved weld joint between the first and second positionsof the curved weld joint (block 536). For example, the calibration tooland/or the welding torch 14 may be used to identify the curved weldjoint between the first and second positions of the curved weld joint.In addition, the one or more cameras may be used to track thecalibration tool and/or the welding torch 14 to determine a positionand/or an orientation of the calibration tool and/or the welding torch14 for detecting the curved portion of the curved weld joint. As may beappreciated, during operation, the first position may be detected, thenthe curved weld joint may be detected, and then the second position maybe detected. However, the detection of the first position, the secondposition, and the curved weld joint may occur in any suitable order. Incertain embodiments, a representation of the curved portion of thecurved weld joint may be stored for determining a quality of a weldingoperation by comparing a position and/or an orientation of the weldingtorch 14 during the welding operation to the stored representation ofthe curved portion of the curved weld joint. As may be appreciated, incertain embodiments, the welding operation may be a multi-pass weldingoperation.

Moreover, calibration for some joints, such as circular weld joints(e.g., pipe joints) may be performed by touching the calibration tool tothree different points around the circumference of the circular weldjoint. A path of the circular weld joint may then be determined bycalculating a best-fit circle that intersects all three points. The pathof the circular weld joint may be stored and used to evaluate weldingparameters of training welds. For a more complex geometry, thecalibration tool and/or the welding torch 14 might be dragged along theentire joint in order to indicate the joint to the system so that all ofthe parameters may be calculated.

In some embodiments, the method 530 for calibrating a curved weld jointthat may be used with the welding system 10 may not utilize the weldingtorch 14 or the calibration tool to determine the path of the weldjoint. That is, the control circuitry 52 may utilize one or more imagescaptured by cameras (e.g., such as one or more cameras of the sensingsystem 16) to detect the first position (block 532), the second position(block 534), and the curved portion (block 536) of the weld joint.Additionally, or in the alternative, the control circuitry 52 mayutilize one or more emitters (e.g., emitters 105, 109) to emit a visiblepattern (e.g., grid, point field) onto the workpiece 82 and weld joint.Cameras configured to detect the visible pattern may determine the shapeof the workpiece 82 and/or the path of the weld joint based onparticular features of the shape and orientation of the visible patternon the workpiece 82 and weld joint. The control circuitry 52 maydetermine the shape of the weld joint and/or the workpiece 82 utilizingobject recognition algorithms (e.g., edge detection) applied to the oneor more captured images or visible pattern. The operator may provideinput to aid the object recognition, such as selecting a type of joint(e.g., butt, tee, lap, corner, edge) and/or the shape (e.g., planar,tubular, curved) of the workpiece 82.

FIG. 38 is a diagram of an embodiment of a curved weld joint 538. Such acurved weld joint 538 may be calibrated using the method 530 describedin FIG. 37. The curved weld joint 538 is on a workpiece 540.Specifically, the curved weld joint 538 includes a first position 542, asecond position 544, and a curved portion 546. Using the method 530, ashape of the curved weld joint 538 may be determined and/or stored forevaluating a welding operator performing a welding operation on thecurved weld joint 538.

FIG. 39 is a diagram of an embodiment of a complex shape workpiece 539with a curved weld joint 541. The curved weld joint 541 may becalibrated via markers 543 added to the workpiece 539 (e.g., near thecurved weld joint 541). A marking tool 545 may apply the markers 543 tothe workpiece 539. The marking tool 545 may be a manual marking tool 545with a handle 557. The markers 543 may include, but are not limited topaints, inks, pigments, stickers (e.g., tape), or reflectors applied tothe workpiece 539 via the marking tool 545. The operator may roll amarking wheel 547 of the marking tool 545 along the curved weld joint541, depositing (e.g., transferring) the markers 543 on the workpiece539 to be utilized during a live welding session. For example, one ormore applicators 549 on the marking wheel 547 may apply the markers 543to the workpiece 539. In some embodiments, the markers 543 (e.g., paint,ink, pigment) may be removed from the workpiece 539 upon completion ofperforming the weld along the weld joint 541. That is, the markers 543may be washed or scrubbed off the workpiece 539. The one or moreapplicators 549 are arranged about the marking tool 545 to facilitateplacing one or more markers in a repeating pattern along a path of theworkpiece. For example, the one or more applicators 549 may be arrangedabout a circumference 551 of the marking wheel 547 such that one periodof the pattern of the one or more markers 543 is applied to theworkpiece 539 for each revolution of the marking wheel 547. In someembodiments, the applicators 549 are configured to apply paint (e.g.,reflective paint, fluorescent paint) from a reservoir of the markingtool 545 as each applicator 549 interfaces with the workpiece 539.Moreover, the applicators 549 may be a sorbent material that storespaint or ink.

Cameras of the sensing device 16 on the stand 12 and/or integrated withthe helmet 41 of the welding system 10 may detect the markers 543.Control circuitry of the welding system 10 may determine the shape ofthe complex shape workpiece 539 and/or the welding system 10 maydetermine the welding path along the curved weld joint 541 based atleast in part on the detected markers 543. The shape of the complexshape workpiece 539 and/or the welding path of the curved weld joint 541may be stored for evaluating a welding operator performing a weldingoperation on the curved weld joint 541. While the markers 543 shown inFIG. 39 are discontinuous, some embodiments of the markers 543 may becontinuous along the curved weld joint 541.

As may be appreciated, embodiments of the one or more markers 543 mayinclude various geometric shapes, curves, lines, pictures, text, logos,or any combination thereof. FIGS. 72-75 illustrate embodiments ofmarkers 543 that may be applied to the workpiece 539 by the marking tool545. Each of FIGS. 72-75 illustrates a respective embodiment of a marker543 having known properties (e.g., length 561, width 563, direction 565,shape, radius). In some embodiments, markers 543 are asymmetric aboutthe direction 565 (e.g., markers of FIGS. 73-75), asymmetric in about atransverse direction 593 (e.g., marker of FIG. 72), or asymmetric aboutboth directions 565 and 593.

For example, the logo marker embodiment of FIG. 75 includes a pictureand text that corresponds to the tool manufacturer and/or seller. Insome embodiments, each marker 543 has an endpoint 567 that demarcatesthe beginning and/or the end of the respective marker 543. Moreover,features (e.g., arrows 569, text direction, unique portions) of themarker 543 may facilitate correspondence of the known properties of themarker 543 with images captured by the sensing device 16 (e.g., camera).In some embodiments, the period of each marker 543 includes one or moreunmarked lengths 555 (e.g., gaps), as shown by the dashed line markers543 proximate the joint 541 of FIG. 39. As discussed below, comparisonof observed properties of a pattern of markers 543 with the knownproperties of the markers 543 facilitates the determination of theshapes of workpiece components with the pattern of markers 543 and thedetermination of the weld joint 541 between the workpiece components. Insome embodiments, the pattern of markers 543 may be a continuous linewith known properties (e.g., length, width).

FIG. 76 illustrates an embodiment of a welding system with workpiececomponents 569, 571 to be joined along a weld joint 573. As discussedherein, the term workpiece includes embodiments of separate pieces(e.g., first component 569, second component 571) to be welded together.A first surface 575 of the first component 569 has a first pattern 577of markers 543 (e.g., triangles) observable by the camera 579. As may beappreciated, the camera 579 may be a camera of the sensing device 16,such as a camera 579 coupled to and/or integrated with the weldinghelmet 41. In some embodiments, the camera 579 is coupled to the weldingtorch 14. Captured images of the first pattern 577 of markers 543 may beused to determine the plane of the first surface 575. Comparison ofobserved properties (e.g., marker length, marker width, marker radius)of a marker 543 of the first pattern 577 with the known properties ofthe marker 543 may be utilized to determine the position (e.g., radialdistance, height, azimuth) of the marker 543 relative to the camera 579.In some embodiments, the known properties of the marker 543 may includethe marker width for each point along the marker length. Comparison ofthe observed marker width at a point with the known marker width at thepoint may facilitate determining the position and/or the orientation ofthe respective marker 543 relative to the camera 579. The determinedposition of multiple markers (or points within the markers) of the firstpattern 577 may facilitate the determination of the plane of the firstsurface 575. In a similar manner, captured images of a second pattern581 of markers 543 on a second surface 583 of the second component 571may facilitate the determination of the plane of the second surface 583.The location of the joint 573 may then be determined as the intersectionof the determined plane of the first surface 575 with the determinedplane of the second surface 583. While the embodiments of the firstpattern 577 and the second pattern 581 each have a plurality (e.g.,three) of full length adjacent markers 543, it may be appreciated thatpatterns of markers 543 with portions of a period of a marker 543 may beutilized to determine the plane and the location of the joint 573.Moreover, the positions of the markers 543, the planes of the surfaces575 and 583, and the location of the joint 573 may be determined by oneor more algorithms executed by the computer 18.

In some embodiments, the respective surface of the components and thejoint 573 may be determined by comparing observed properties of themarkers 543 with the known properties of the markers 543. For example,the computer 18 may determine the position of a first marker 585 bycomparing the observed length and width of the first marker 585 to theknown length 561 and width 563 of the first marker 585. The computer 18may also determine the direction 565 of the first marker 585, therebyenabling the computer 18 to estimate the position of an adjacent secondmarker 587. That is, the markers 543 of a pattern (e.g., first pattern577) applied to a workpiece component may be detected by the camera 579in substantially any orientation (e.g., parallel, perpendicular, askew)relative to the joint 573. Comparison of the observed properties of thesecond marker 587 with estimated or observed properties of the secondmarker 587 may facilitate the determination of the shape of the firstsurface 575. For example, the observed differences of the markers 543 ofthe first pattern 577 applied to a planar component (e.g., first surface575) may be recognizably different than the observed differences of themarkers 543 of a third pattern 589 applied to a curved (e.g., circular)component 591. The differences (e.g., distortion) between the observedproperties of the markers 543 relative to the known properties of themarkers 543 may be utilized to determine the position and/or theorientation of the markers 543 on the surface of the workpiece.Moreover, differences (e.g., distortion) between the observed propertiesof the markers 543 within a repeating pattern on the same surface may beutilized to determine the shape of the workpiece.

FIG. 40 is an embodiment of a method 548 for tracking a multi-passwelding operation. One or more cameras (e.g., such as one or morecameras of the sensing system 16) are used to detect a first pass of thewelding torch 14 along a weld joint during the multi-pass weldingoperation (block 550). Moreover, the one or more cameras are used todetect a second pass of the welding torch 14 along the weld joint duringthe multi-pass welding operation (block 552). Furthermore, the one ormore cameras are used to detect a third pass of the welding torch 14along the weld joint during the multi-pass welding operation (block554). The control circuitry 52 (or control circuitry of another device)may be configured to store a representation of the first pass, thesecond pass, and/or the third pass together as a single weldingoperation for determining a quality of the multi-pass welding operation.As may be appreciated, the multi-pass welding operation may be a livewelding operation, a training welding operation, a virtual realitywelding operation, and/or an augmented reality welding operation.

FIG. 41 is a perspective view of an embodiment of the welding stand 12.The welding stand 12 includes the welding surface 88 supported by thelegs 90. Moreover, the welding surface 88 includes one or more slots 91to facilitate positioning of a workpiece on the welding surface 88.Furthermore, the welding surface 88 includes multiple apertures 556(e.g., holes or openings) that extend through the welding surface 88.The apertures 556 may be used to enable the sensing device 16 todetermine a position and/or an orientation of the welding surface 88.Specifically, markers may be arranged below the apertures 556, yetwithin the view of the sensing device 16 to enable the sensing device 16to determine the position and/or the orientation of the welding surface88. The markers may be arranged below the welding surface 88 tofacilitate longer lasting markers and/or to block debris from coveringthe markers, as explained in greater detail in relation to FIG. 42.

Drawers 558 are attached to the welding stand 12 to enable storage ofvarious components with the welding stand 12. Moreover, wheels 560 arecoupled to the welding stand 12 to facilitate easily moving the weldingstand 12. Adjacent to the drawers 558, a calibration tool holder 562 anda welding torch holder 564 enable storage of a calibration tool and thewelding torch 14. In certain embodiments, the welding system 10 may beconfigured to detect that the calibration tool is in the calibrationtool holder 562 at various times, such as before performing a weldingoperation. A support structure 566 extending vertically from the weldingsurface 88 is used to provide structure support to the sensing device 16and the display 32. Moreover, a tray 568 is coupled to the supportstructure 566 to facilitate storage of various components.

The protective cover 102 is positioned over the display 32 to blockcertain environmental elements from contacting the display 32 (e.g.,weld spatter, smoke, sparks, heat, etc.). A handle 570 is coupled to theprotective cover 102 to facilitate rotation of the protective cover 102from a first position (as illustrated) used to block certainenvironmental elements from contacting the display 32 to a second raisedposition away from the display 32, as illustrated by arrows 572. Thesecond position is not configured to block the environmental elementsfrom contacting the display 32. In certain embodiments, the protectivecover 102 may be held in the first and/or the second position by alatching device, a shock, an actuator, a stop, and so forth.

A switch 573 is used to detect whether the protective cover 102 is inthe first position or in the second position. Moreover, the switch 573may be coupled to the control circuitry 52 (or control circuitry ofanother device) and configured to detect whether the protective cover102 is in the first or the second position and to block or enablevarious operations (e.g., live welding, auxiliary power, etc.) while theswitch 573 detects that the protective cover 102 is in the first and/orthe second position. For example, if the switch 573 detects that theprotective cover 102 is in the second position (e.g., not properlycovering the display 32), the control circuitry 52 may block livewelding and/or simulation welding (with the protective cover 102 in thesecond position the sensing device 16 may be unable to accurately detectmarkers). As another example, if the switch 573 detects that theprotective cover 102 is in the second position, control circuitry of thewelding stand 12 may block the availability of power provided to anoutlet 574 of the welding stand 12. In certain embodiments, the display32 may show an indication that the protective cover 102 is in the firstand/or the second position. For example, while the protective cover 102is in the second position, the display 32 may provide an indication tothe welding operator that live welding and/or power at the outlet 574are unavailable. The welding stand 12 includes speakers 575 to enableaudio feedback to be provided to a welding operator using the weldingstand 12. Furthermore, in certain embodiments, if the trigger of thewelding torch 14 is actuated while the protective cover 102 is in thesecond position, the welding system 10 may provide visual and/or audiofeedback to the operator (e.g., the welding system 10 may provide avisual message and an audible sound effect).

As illustrated, the support structure 566 includes a first arm 576 and asecond arm 578. The first and second arms 576 and 578 are rotatableabout the support structure 566 to enable the first and second arms 576and 578 to be positioned at a selected height for vertical and/oroverhead welding. In the illustrated embodiment, the first and secondarms 576 and 578 are independently (e.g., separately) rotatable relativeto one another so that the first arm 576 may be positioned at a firstvertical position while the second arm 578 may be positioned at a secondvertical position different from the first vertical position. In otherembodiments, the first and second arms 576 and 578 are configured torotate together. Moreover, in certain embodiments, the first and secondarms 576 and 578 may be rotated independently and/or together based on aselection by a welding operator. As may be appreciated, in otherembodiments, arms may not be coupled to the support structure 566, butinstead may be positioned at other locations, such as being positionedto extend vertically above one or more front legs, etc. Furthermore, insome embodiments, a structure may be coupled to the welding stand 12 tofacilitate a welding operator leaning and/or resting thereon (e.g., aleaning bar).

Each of the first and second arms 576 and 578 includes a shock 580 (oranother supporting device) that facilitates holding the first and secondarms 576 and 578 in selected vertical positions. Moreover, each of thefirst and second arms 576 and 578 includes a braking system 582configured to lock the first and second arms 576 and 578 individually inselected positions. In certain embodiments, the braking system 582 isunlocked by applying a force to a handle, a switch, a pedal, and/oranother device.

The workpiece 82 is coupled to the second arm 578 for overhead and/orvertical welding. Moreover, the first arm 576 includes the welding plate108 for overhead, horizontal, and/or vertical welding. As may beappreciated, the workpiece 82, the welding plate 108, and/or a clampused to hold the welding plate 108 may include multiple markers (e.g.,reflective and/or light emitting) to facilitate tracking by the sensingdevice 16. For example, in certain embodiments, the workpiece 82, thewelding plate 108, and/or the clamp may include three markers on onesurface (e.g., in one plane), and a fourth marker on another surface(e.g., in a different plane) to facilitate tracking by the sensingdevice 16. As illustrated, a brake release 584 is attached to each ofthe first and second arms 576 and 578 for unlocking each braking system582. In certain embodiments, a pull chain may extend downward from eachbrake release 584 to facilitate unlocking and/or lowering the first andsecond arms 576 and 578, such as while the brake release 584 of thefirst and second arms 576 and 578 are vertically above the reach of awelding operator. Thus, the welding operator may pull a handle of thepull chain to unlock the braking system 582 and/or to lower the firstand second arms 576 and 578.

As illustrated, the second arm 578 includes a clamp assembly 588 forcoupling the workpiece 82 to the second arm 578. Moreover, the clampassembly 588 includes multiple T-handles 590 for adjusting, tightening,securing, and/or loosening clamps and other portions of the clampassembly 588. In certain embodiments, the first arm 576 may also includevarious T-handles 590 for adjusting, tightening, securing, and/orloosening the welding plate 108. As may be appreciated, the clampassembly 588 may include multiple markers (e.g., reflective and/or lightemitting) to facilitate tracking by the sensing device 16. For example,in certain embodiments, the clamp assembly 588 may include three markerson one surface (e.g., in one plane), and a fourth marker on anothersurface (e.g., in a different plane) to facilitate tracking by thesensing device 16. It should be noted that the welding system 10 mayinclude the clamp assembly 588 on one or both of the first and secondarms 576 and 578.

The sensing device 16 includes a removable cover 592 disposed in frontof one or more cameras of the sensing device 16 to block environmentalelements (e.g., spatter, smoke, heat, etc.) or other objects fromcontacting the sensing device 16. The removable cover 592 is disposed inslots 594 configured to hold the removable cover 592 in front of thesensing device 16. In certain embodiments, the removable cover 592 maybe inserted, removed, and/or replaced without the use of tools. Asexplained in detail below, the removable cover 592 may be disposed infront of the sensing device 16 at an angle to facilitate infrared lightpassing therethrough.

As illustrated, a linking assembly 596 may be coupled between the firstand/or second arms 576 and 578 and the sensing device 16 to facilitaterotation of the sensing device 16 as the first and/or second arms 576and 578 are rotated. Accordingly, as the first and/or second arms 576and 578 are rotated, the sensing device 16 may also rotate such that oneor more cameras of the sensing device 16 are positioned to track aselected welding surface. For example, if the first and/or second arms576 and 578 are positioned in a lowered position, the sensing device 16may be configured to track welding operations that occur on the weldingsurface 88. On the other hand, if the first and/or second arms 576 and578 are positioned in a raised position, the sensing device 16 may beconfigured to track vertical, horizontal, and/or overhead weldingoperations. In some embodiments, the first and/or second arms 576 and578 and the sensing device 16 may not be mechanically linked, yetrotation of the first and/or second arms 576 and 578 may facilitaterotation of the sensing device 16. For example, markers on the firstand/or second arms 576 and 578 may be detected by the sensing device 16and the sensing device 16 may move (e.g., using a motor) based on thesensed position of the first and/or second arms 576 and 578.

In some embodiments, movement of the first and/or second arms 576, 578may at least partially invalidate previous calibrations of the sensingdevice 16 with components of the training stand 12. For example, afterthe sensing device 16 is calibrated with the main (e.g., horizontal)welding surface 88 of the training stand 12, subsequent movement of thefirst and second arms 576, 578 may invalidate the calibration of themain welding surface 88 based at least in part on movement of thesensing device 16. Accordingly, the sensing device 16 may berecalibrated with the main welding surface 88 after the operatorperforms welding sessions that utilize the first and/or second arms 576,578. In some embodiments, the computer 18 notifies the operator via thedisplay 32 and/or audible notifications when the sensing device 16 is tobe recalibrated based on detected movement of the sensing device 16relative to the welding surface 88. Additionally, or in the alternative,the display 62 of the welding torch 14 may notify the operator when thesensing device 16 is to be recalibrated.

FIG. 42 is a cross-sectional view of an embodiment of the weldingsurface 88 of the welding stand 12 of FIG. 41. As illustrated, thewelding surface 88 includes multiple apertures 556 extendingtherethrough between an upper plane 597 of the welding surface 88 and alower plane 598 of the welding surface 88. A bracket 599 is positionedbeneath each aperture 556. The brackets 599 may be coupled to thewelding surface 88 using any suitable fastener or securing means. In theillustrated embodiment, the brackets 599 are coupled to the weldingsurface 88 using fasteners 600 (e.g., bolts, screws, etc.). In otherembodiments, the brackets 599 may be welded, bonded, or otherwisesecured to the welding surface 88. Moreover, in certain embodiments, thebrackets 599 may be mounted to a lateral side of the welding stand 12rather than the welding surface 88. Markers 602 are coupled to thebrackets 599 and positioned vertically below the apertures 556, but themarkers 602 are horizontally offset from the apertures 556 to block dustand/or spatter from contacting the markers 602 and to enable the sensingdevice 16 to sense the markers 602. In some embodiments, the markers 602may be positioned within the apertures 556 and/or at any location suchthat the motion tracking system is positioned on one side of the upperplane 597 and the markers 602 are positioned on the opposite side of theupper plane 597. As may be appreciated, the markers 602 may be lightreflective and/or light-emissive (e.g., LEDs 64). For example, incertain embodiments, the markers 602 may be formed from a lightreflective tape and/or retroflectors. In some embodiments, the markers602 may be spherical markers. Accordingly, the sensing device 16 maydetect the markers 602 to determine a position and/or an orientation ofthe welding surface 88.

FIG. 43 is a cross-sectional view of an embodiment of the sensing device16 having the removable cover 592. As illustrated, the removable cover592 is disposed in the slots 594. The sensing device 16 includes acamera 604 (e.g., infrared camera) having a face 605 on a side of thecamera 604 having a lens 606. The removable cover 592 is configured toenable infrared light to pass therethrough and to block environmentalelements (e.g., spatter, smoke, heat, etc.) or other objects fromcontacting the lens 606 of the camera 604. As may be appreciated, thecamera 604 may include one or more infrared emitters 607 configured toemit infrared light. If the removable cover 592 is positioned directlyin front of the face 605, a large amount of the infrared light from theinfrared emitters 607 may be reflected by the removable cover 592 towardthe lens 606 of the camera 604. Accordingly, the removable cover 592 ispositioned at an angle 608 relative to the face 605 of the camera 604 todirect a substantial portion of the infrared light from being reflectedtoward the lens 606. Specifically, in certain embodiments, the removablecover 592 may be positioned with the angle 608 between approximately 10to 60 degrees relative to the face 605 of the camera 604. Moreover, inother embodiments, the removable cover 592 may be positioned with theangle 608 between approximately 40 to 50 degrees (e.g., approximately 45degrees) relative to the face 605 of the camera 604. The removable cover592 may be manufactured from any suitable light-transmissive material.For example, in certain embodiments, the removable cover 592 may bemanufactured from a polymeric material, or any other suitable material.

FIG. 44 is a perspective view of an embodiment of a calibration tool610. As may be appreciated, the calibration tool 610 may be used tocalibrate a workpiece, a work surface, a weld joint, and so forth, for awelding operation. The calibration tool 610 includes a handle 612 tofacilitate gripping the calibration tool 610. Moreover, the calibrationtool 610 is configured to be detected by the sensing device 16 fordetermining a spatial position that a tip 614 of the calibration tool610 is contacting. In certain embodiments, the computer 18 coupled tothe sensing device 16 may be configured to determine a calibration pointmerely by the tip 614 contacting a specific surface. In otherembodiments, the computer 18 is configured to determine a calibrationpoint by a welding operator providing input indicating that the tip 614is contacting a calibration point. Furthermore, in the illustratedembodiment, the computer 18 is configured to detect a calibration pointby the tip 614 contacting the calibration point while a downward forceis applied to the calibration tool 610 via the handle. The downwardforce directs a distance between two adjacent markers to decrease belowa predetermined threshold thereby indicating a selected calibrationpoint. The sensing device 16 is configured to detect the change indistance between the two adjacent markers and the computer 18 isconfigured to use the change in distance to identify the calibrationpoint.

The handle 612 is coupled to a light-transmissive cover 616. Moreover, agasket 618 is coupled to one end of the light-transmissive cover 616,while an end cap 620 is coupled to an opposite end of thelight-transmissive cover 616. During operation, as a downward force isapplied to the calibration tool 610 using the handle 612, a distance 622between the tip 613 and the gasket 618 decreases.

FIG. 45 is a perspective view of the calibration tool 610 of FIG. 43having the outer cover 616 removed. The calibration tool 610 includes afirst portion 624 having a first shaft 626. Moreover, the first shaft626 includes the tip 614 on one end, and a bearing 628 (or mountingstructure) on an opposite end. In certain embodiments, the bearing 628has a cup like structure configured to fit around a contact tip of thewelding torch 14. Furthermore, the first shaft 626 includes a firstmarker 630 and a second marker 632 coupled thereto. The calibration tool610 also includes a second portion 634 having a second shaft 636 with athird marker 638 coupled thereto. A spring 640 is disposed around thesecond shaft 636 between the third marker 638 and the bearing 628. Asmay be appreciated, the spring 640 facilitates the third marker 638being directed toward the second marker 632. For example, as a downwardforce is applied to the calibration tool 610 using the handle 612, thespring 640 is compressed to decrease a first distance 642 between thesecond and third markers 632 and 638. In contrast, as the downward forceis removed from the calibration tool 610, the spring 640 is decompressedto increase the first distance 642 between the second and third markers632 and 638. A second distance 644 between the first and second markers630 and 632 is fixed, and a third distance 646 between the first marker630 and the tip 614 is also fixed.

In certain embodiments, the welding system 10 uses the calibration tool610 to detect calibration points using a predetermined algorithm. Forexample, the third distance 646 between the tip 614 and the closestmarker to the tip 614 (e.g., the first marker 630) is measured. Thethird distance 646 is stored in memory. The second distance 644 betweentwo fixed markers (e.g., the first marker 630 and the second marker 632)is measured. The second distance 644 is also stored in memory.Furthermore, a compressed distance between the markers (e.g., the secondand third markers 632 and 638) with the spring 640 disposed therebetweenis measured. A line is calculated between the two fixed markers usingtheir x, y, z locations. The line is used to project a vector along thatline with a length of the third distance 646 starting at the firstmarker 630 closest to the tip 614. The direction of the vector may beselected to be away from the compressed markers. Accordingly, the threedimensional location of the tip may be calculated using the markers. Insome embodiments, only two markers may be used by the calibration tool610. In such embodiments, an assumption may be made that the markerclosest to the tip 614 is the marker closest to the work surface (e.g.,table or clamp). Although the calibration tool 610 in the illustratedembodiment uses compression to indicate a calibration point, thecalibration tool 610 may indicate a calibration point in any suitablemanner, such as by uncovering a marker, covering a marker, turning on anLED (e.g., IR LED), turning off an LED (e.g., IR LED), enabling and/ordisabling a wireless transmission to a computer, and so forth.

The first, second, and third markers 630, 632, and 638 are spherical, asillustrated; however, in other embodiments, the first, second, and thirdmarkers 630, 632, and 638 may be any suitable shape. Moreover, thefirst, second, and third markers 630, 632, and 638 have a reflectiveouter surface and/or include a light-emitting device. Accordingly, thefirst, second, and third markers 630, 632, and 638 may be detected bythe sensing device 16. Therefore, the sensing device 16 is configured todetect the first, second, and third distances 642, 644, and 646. As thefirst distance 642 decreases below a predetermined threshold, thecomputer 18 is configured to identify a calibration point. As may beappreciated, the first, second, and third distances 642, 644, and 646are all different to enable the sensing device 16 and/or the computer 18to determine a location of the tip 614 using the location of first,second, and third markers 630, 632, and 638.

To calibrate a workpiece, the workpiece may first be clamped to thewelding surface 88. After the workpiece is clamped to the weldingsurface 88, a welding operator may provide input to the welding system10 to signify that the workpiece is ready to be calibrated. In certainembodiments, the clamp used to secure the workpiece to the weldingsurface 88 may include markers that facilitate the welding system 10detecting that the workpiece is clamped to the welding surface 88. Afterthe welding system 10 receives an indication that the workpiece isclamped to the welding surface 88, the welding operator uses thecalibration tool 610 to identify two calibration points on the workpiece82. Where the clamp assembly 588 securing the workpiece has markers(e.g., visual markers 802), the measurements of the joint calibrationtool 610 may be relative to the markers of the clamp assembly 588.Accordingly, the computer 18 may compensate for movement of theworkpiece 82 and/or clamp assembly 588 after the joint has beencalibrated based on identification of the clamp markers. Specifically,in the illustrated embodiment, the welding operator touches the tip 614to a first calibration point and applies downward force using the handle612 until the welding system 10 detects a sufficient change in distancebetween adjacent markers, thereby indicating the first calibrationpoint. Furthermore, the welding operator touches the tip 614 to a secondcalibration point and applies downward force using the handle 612 untilthe welding system 10 detects a sufficient change in distance betweenadjacent markers, thereby indicating the second calibration point. Incertain embodiments, the welding system 10 will only detect acalibration point if the calibration tool 610 is pressed and held at thecalibration point for a predetermine period of time (e.g., 0.1., 0.3,0.5, 1.0, 2.0 seconds, and so forth). The welding system 10 may beconfigured to capture multiple calibration points (e.g., 50, 100, etc.)over the predetermined period of time and average them together. Ifmovement of the multiple calibration points greater than a predeterminedthreshold is detected, the calibration may be rejected and done over.Furthermore, if a first point is successfully calibrated, a second pointmay be required to be a minimum distance away from the first point(e.g., 2, 4, 6 inches, etc.). If the second point is not the minimumdistance away from the first point, calibration of the second point maybe rejected and done over. The welding system 10 uses the twocalibration points to calibrate the workpiece.

In certain embodiments, the welding system 10 may determine a virtualline between the first and second calibration points. The virtual linemay be infinitely long and extend beyond the first and secondcalibration points. The virtual line represents a weld joint. Variouswelding parameters (e.g., work angle, travel angle, contact tip-to-workdistance (CTWD), aim, travel speed, etc.) may be in reference to thisvirtual line. Accordingly, the virtual line may be important forcalculating the various welding parameters.

It should be noted that in certain embodiments the first, second, andthird markers 630, 632, and 638 are all disposed vertically above thehandle 612, while in other embodiments, one or more of the first,second, and third markers 630, 632, and 638 are disposed verticallybelow the handle 612 to enable a greater distance between adjacentmarkers. In certain embodiments, the first portion 624 may be removedfrom the calibration tool 610 and coupled to a contact tip of thewelding torch 14 for calibrating the welding torch 14. As may beappreciated, the tip 614 of the calibration tool 610 may be any suitableshape. FIGS. 46 through 48 illustrate a few embodiments of shapes thetip 614 may have.

Specifically, FIG. 46 is a side view of an embodiment of a pointed tip648 of the calibration tool 610. Using the pointed tip 648, thecalibration tool 610 may be used for calibrating various joints on theworkpiece 82, such as the illustrated fillet joint, a lap joint, a buttjoint with no root opening, and so forth. Moreover, FIG. 47 is a sideview of an embodiment of a rounded tip 650 of the calibration tool 610.Using the rounded tip 650, the calibration tool 610 may be used forcalibrating various joints on the workpiece 82, such as the illustratedfillet joint, a butt joint with a root opening, a lap joint, and soforth. Furthermore, FIG. 48 is a side view of an embodiment of therounded tip 650 of the calibration tool 610 having a small pointed tip652. Using the small pointed tip 652 on the end of the rounded tip 650,the calibration tool 610 may be used for calibrating various joints onthe workpiece 82, such as the illustrated butt joint with no rootopening, a filled joint, a lap joint, and so forth. In certainembodiments, the tip of the calibration tool 610 may be removable and/orreversible, such that the tip includes two different types of tips(e.g., one type of tip on each opposing end). Accordingly, a weldingoperator may select the type of tip used by the calibration tool 610. Incertain embodiments, one or more markers may be coupled to thecalibration tool 610 if the calibration tool 610 is reversible. The oneor more markers may be used to indicate which side of the tip is beingused so that the welding system 10 may use a suitable marker-tipdistance for calibration calculations.

FIG. 49 is an embodiment of a method 654 for detecting a calibrationpoint. The sensing device 16 (or another component of the welding system10) detects a first marker of the calibration tool 610, a second markerof the calibration tool 610, and/or a third marker of the calibrationtool 610 (block 656). Moreover, the welding system 10 determines a firstdistance between the first marker and the second marker and/or a seconddistance between the second marker and the third marker (block 658).Furthermore, the welding system 10 detects whether the first distance orthe second distance is within a predetermined distance range (e.g.,signifying a compressed distance) (block 660).

The welding system 10 determines a position of a calibration point ifthe first distance or the second distance is within the predetermineddistance range (e.g., signifying a compressed distance) (block 662). Inaddition, the welding system 10 determines a location of a calibrationtip of the calibration tool 610 relative to at least one of the first,second, and third markers to determine the spatial position of thecalibration point (block 664).

FIG. 50 is an embodiment of a method 666 for determining a welding scorebased on a welding path. Accordingly, the method 666 may be used forevaluating a welding operation. The sensing device 16 (or any suitablemotion tracking system) detects an initial position of the weldingoperation (block 668). Moreover, the sensing device 16 detects aterminal position of the welding operation (block 670). In addition, thesensing device 16 detects a spatial path of the welding operationbetween the initial position and the terminal position (block 672). Forexample, the sensing device 16 tracks a position and/or an orientationof the welding operation. The welding system 10 determines a score ofthe welding operation based at least partly on the spatial path of thewelding operation (e.g., whether the welding operation receives apassing score based on the spatial path of the welding operation) (block674). For example, in certain embodiments, the spatial path of thewelding operation may alone be used to determine whether a welding scorefails. In some embodiments, the sensing device 16 may be used to detecta calibration point that corresponds to the initial position and/or acalibration point that corresponds to the terminal position.

For example, in certain embodiments, the welding system 10 determineswhether the welding operation receives a passing score by determiningwhether: a distance of the path of the welding operation is greater thana predetermined lower threshold, the distance of the path of the weldingoperation is less than the predetermined lower threshold, the distanceof the path of the welding operation is greater than a predeterminedupper threshold, the distance of the path of the welding operation isless than the predetermined upper threshold, the path of the weldingoperation deviates substantially from a predetermined path of thewelding operation, the path of the welding operation indicates thatmultiple welding passes occurred at a single location along a weldjoint, a time of welding along the path of the welding operation isgreater than a predetermined lower threshold, the time of welding alongthe path of the welding operation is less than the predetermined lowerthreshold, the time of welding along the path of the welding operationis greater than a predetermined upper threshold, and/or the time ofwelding along the path of the welding operation is less than thepredetermined upper threshold.

Moreover, in some embodiments, for the welding system 10 to determine ascore, the welding system 10 may disregard a first portion of the pathadjacent to the initial position and a second portion of the pathadjacent to the terminal position. For example, the first portion of thepath and the second portion of the path may include a distance ofapproximately 0.5 inches. Moreover, in other embodiments, the firstportion of the path and the second portion of the path may includeportions of the path formed during a time of approximately 0.5 seconds.

FIG. 51 is an embodiment of a method 676 for transitioning betweenwelding modes using a user interface of the welding torch 14. Thecontrol circuitry 52 of the welding torch 14 (or control circuitry ofanother device) detects a signal produced by a user interface of thewelding torch 14 indicating a request to change the welding mode (e.g.,welding training mode) (block 678). Moreover, the control circuitry 52determines a length of time that the signal is detected (block 680). Thecontrol circuitry 52 is configured to change the welding mode from asimulation mode (e.g., virtual reality mode, augmented reality mode,etc.) to a live welding mode if the length of time that the signal isdetected is greater than a predetermined threshold (block 682).Conversely, the control circuitry 52 is configured to change the weldingmode from the live welding mode to the simulation mode merely if thesignal is detected (block 684) (e.g., there is no length of time thatthe signal is to be detected before a transition from the live weldingmode is made). The control circuitry 52 is configured to direct thewelding torch 14 to vibrate after changing to the live welding mode(block 686). For example, the control circuitry 52 may be configured todirect the welding torch 14 to vibrate two or more times (e.g.,vibration pulses) to indicate a change to the live welding mode.

Moreover, the control circuitry 52 may be configured to direct thewelding torch 14 to vibrate any suitable number of times (e.g.,predetermined number of times) to indicate a change to the live weldingmode. As may be appreciated, the signal indicating the request to changethe welding mode may be produced by pressing a button on the userinterface of the welding torch 14. As such, the welding mode may bechanged from the live welding mode by pressing and releasing the button(e.g., the button does not have to be held down for a predeterminedperiod of time). In contrast, the welding mode may be changed from thesimulation mode to the live welding mode by pressing and holding thebutton for a predetermined period of time. In certain embodiments, anaudible sound may be produced after changing welding modes. Furthermore,in some embodiments an audible sound and a vibration may accompany anychange between welding modes. In addition, a display of the weldingtorch 14 may show the welding mode after changing the welding mode. Insome embodiments, the display may flash the welding mode on the displaya predetermined number of times.

FIG. 52 is a block diagram of an embodiment of a remote training system,such as a helmet training system 41. In some embodiments, the helmettraining system 41 facilitates acquisition of welding parameters (e.g.,a work angle, a travel angle, a contact tip to workpiece distance, awelding torch travel speed, a welding torch orientation, a welding torchposition, an aim of the welding torch relative to the joint of theworkpiece, and so forth) of a weld process and/or arc parameters (e.g.,a welding voltage, a welding current, wire feed speed) without utilizingthe stand 12 described above. As may be appreciated, operators utilizehelmets during welding, and the helmet training system 41 integrates theone or more sensing devices 16 (e.g., emitters, receivers) into thehelmet. Various embodiments of the helmet 41 may incorporate thecomputer 18 (e.g., as a controller), couple to the computer 18 via awired connection, or couple to the computer via a wireless connection.In some embodiments, the helmet training system 41 utilizes a lens 700to shield the operator from the arc during a weld process. In someembodiments, the display 32 is disposed within the helmet trainingsystem 41 such that the operator may view the display 32 and the lens700 in preparation for or during a weld process. The display 32 may be aheads-up display that is at least partially overlaid with the operator'sview through the helmet training system 41. As may be appreciated, thewelding software may utilize the display 32 disposed within the helmettraining system 41 to present information to the operator in a similarmanner as described above with the display 32 external to the helmet 41.For example, the display 32 of the helmet 41 may shows a visualrepresentation (e.g., number, text, color, arrow, graph) of one or morearc parameters, one or more welding parameters, or any combinationthereof. That is, the display 32 of the helmet 41 may display a visualrepresentation of a welding parameter in relation to a predeterminedthreshold range and/or to a target value for the welding parameteraccording to a selected welding assignment. In some embodiments, thedisplay 32 may show a graphical representation of a welding parameter oran arc parameter in relation to a threshold similar to the displays 62of the torch 14 described above with FIG. 34. Additionally, the display32 of the helmet 41 may show one or more parameters (e.g., arcparameters, welding parameters) before, during, or after the operatorusing the helmet 41 performs a welding session (e.g., weldingassignment).

The helmet training system 41 utilizes one or more integrated sensingdevices 16 to determine the welding parameters from observations of thewelding torch 14 and the workpiece 82. The one or more sensing devices16 of the helmet training system 41 may include one or more receivers702 including, but not limited to, microphones, cameras, infraredreceivers, or any combination thereof. Moreover, in some embodiments,one or more emitters 704 may emit energy signals (e.g., infrared light,visible light, electromagnetic waves, acoustic waves), and reflectionsof the energy signals may be received by the one or more receivers 702.In some embodiments, fiducial points 706 (e.g., markers) of the weldingtorch 14 and/or the workpiece 82 are active markers (e.g., LEDs) thatemit energy signals, as discussed above with FIGS. 31 and 32.Accordingly, the one or more receivers 702 of the helmet training system41 may receive energy signals emitted from active markers. Inparticular, the receivers 702 may identify fiducial points (e.g.,markers) 706 disposed on the workpiece 82, the work environment 708,and/or the welding torch 14, and the receivers 702 may send feedbacksignals to the computer 18 (e.g., controller) that correspond to theidentified fiducial points. As discussed above, arrangements of theidentified fiducial points 706 may enable the sensing device 16 todetermine the position and orientation of the welding torch 14 in thework environment 708. The computer 18 (e.g., controller) may determinethe distances between the fiducial points 706 and may determine thewelding parameters based at least in part on the feedback from thereceivers 702. Additionally, the computer 18 (e.g., controller) may becoupled to sensors within the welding power supply 28, the wire feeder30, and/or the welding torch 14 to determine the arc parameters of thewelding process.

In some embodiments, the helmet training system 41 may determine thetypes of components of the welding system 10 from the identifiedfiducial points. For example, the fiducial points of a TIG welding torchare different than the fiducial points of a MIG welding torch. Moreover,the welding software 244 executed by the computer 18 may control thewelding power supply 28 and/or the wire feeder 30 based at least in parton the determined types of components of the welding system 10. Forexample, the helmet training system 41 may control the arc parameters(e.g., weld voltage, weld current) based on the type of welding torch14, the welding position of the workpiece 82, and/or the workpiecematerial. The helmet training system 41 may also control the arcparameters based on the experience or certification status of theoperator associated with the registration number 293. For example, thehelmet training system 41 may control the welding power supply 28 toreduce the weld current available for selection by an operator with lessthan a predetermined threshold of experience with weld processes onrelatively thin workpieces or in the overhead welding position. In someembodiments, the one or more sensing devices 16 of the helmet trainingsystem 41 include inertial sensors 709 (e.g., gyroscopes andaccelerometers) that are coupled to the computer 18. The inertialsensors 709 may enable the computer 18 to determine the orientation andrelative movement of the helmet training system 41 within theenvironment.

In some embodiments, the helmet training system 41 includes the operatoridentification system 43. The operator identification system 43 mayutilize a scanner 710 (e.g., fingerprint scanner, retinal scanner,barcode scanner) or an input/output device 712 (e.g., keyboard, touchscreen) to receive the identification information from the operator. Asdiscussed above, the identification information may be associated withthe registration number 293 unique to the operator. Welding datareceived by the computer 18 (e.g., controller) may be stored in thememory 22 or storage 24, as discussed above. The computer 18 (e.g.,controller) may associate the received and stored welding data with theregistration number 293 of the identified operator. The network device36 couples to the network 38 via a wired or wireless connection to storethe welding data 327 from the helmet training system 41 in the datastorage system 318 (e.g., cloud storage system). In some embodiments thehelmet training system 41 may store welding data locally within thestorage 24 of the computer 18 while the helmet training system 41 isoperated remotely (e.g., production floor, worksite). The helmettraining system 41 may be configured to upload stored welding data tothe data storage system 318 (e.g., cloud storage system) upon connectionwith the network 38, such as when the operator stows the helmet trainingsystem 41 at the end of a shift or at the end of a work week. In someembodiments, the network device 36 of the helmet training system 41 maystream welding data to the data storage system 318 (e.g., cloud storagesystem) via the network 38 during and/or after the operator performs awelding session.

As may be appreciated, using the systems, devices, and techniquesdescribed herein, a welding system 10 may be provided for trainingwelding operators. The welding system 10 may be cost efficient and mayenable welding students to receive high quality hands on training. Whilethe welding systems 10 described herein may be utilized for receivingand correlating weld data 327 for training and educational purposes, itmay be appreciated that the welding systems 10 described herein may beutilized to monitor operators and obtain weld data 327 from non-trainingweld processes. That is, weld data obtained from non-training weldprocesses may be utilized to monitor weld quality and/or weldproductivity of previously trained operators. For example, the weld data327 may be utilized to verify that welding procedures for a particularweld process were executed. As illustrated in FIG. 52, multiple weldingsystems 10 may be coupled to the data storage system 318 (e.g., cloudstorage system) via the network 38. Accordingly, the data storage system318 may receive welding data 327 associated with registration numbers293 from multiple welding systems 10 (e.g., systems with training stands12, helmet training systems 41). Moreover, welding data associated witheach registration number 293 may include serial numbers 329corresponding to other welding sessions performed by the respectiveoperator. Moreover, as utilized herein, the term “assignment” is not tobe limited to weld tests performed by the operator for training andeducational purposes. That is, assignments may include non-training weldprocesses, training simulated weld processes, and training live weldprocesses, among others. Moreover, the term “welding session” mayinclude, but is not limited to, welding assignments, welds performed ona production floor, welds performed at a worksite, or any combinationthereof.

The welding data 327 of the data storage system 318 (e.g., cloud storagesystem) may be monitored and/or managed via a remote computer 44 coupledto the network 38. The stored welding data 327 corresponds to weldprocesses (e.g., live, simulated, virtual reality) performed by variousoperators at one or more locations. FIG. 53 illustrates an embodiment ofa user viewable dashboard screen 720 that may be utilized by a manageror instructor to monitor and/or analyze the stored welding data 327 inthe data storage system 318. The welding data 327 may be organized bycharacteristics (e.g., filter criteria) of the welding data 327.Characteristics of the welding data 327 that may be utilized for sortingthe welding data 327 may include, but are not limited to, one or moreorganizations 722 (e.g., training center, employer, work site), one ormore groups 724 (e.g., shift) within the organization, one or moreregistration numbers 726 of operators within the selected organizations722 or groups 724, time (e.g., dates 728, time of day) welding processeswere performed, systems 725, and weld identifications 730 (e.g.,particular welding assignments, unique identifier associated with awelding session, workpiece part number, or types of welds). For example,welding data 327 associated with one or more registration numbers 293over a period of time (e.g., dates 728) and across differentorganizations 722 or different groups 724 may be displayed on thedashboard screen 720. Accordingly, the manager or instructor may trackthe progress of an operator over time across different organizations viawelding data associated with the registration number 293 of theoperator. In some embodiments, a welding data type 732 (e.g., livetraining, live non-training, simulated, virtual reality) may be used tofilter the viewed welding data. Moreover, a welding process type 735(e.g., GMAW, TIG, SMAW) may be used to filter the viewed welding data insome embodiments. As may be appreciated, welding data for each weldingsession (e.g., welding assignment) may be sorted (e.g., filtered) intovarious subsets. As illustrated in FIG. 53, live, non-training weldsperformed by an operator with registration number 58,794 on Jun. 25,2014 with system I may be displayed on the dashboard screen 720 viaselection of one or more of the appropriate fields for registrationnumbers 726, systems 725, dates 728, and welding data types 732.

Additionally, or in the alternative, the instructor may utilize a searchcontrol 733 to search for welding data 327 associated with variousparameters (e.g., serial numbers 329, organization 722, group 724,operator name, registration number 726, time, welding data type)corresponding to welding sessions performed by operators. Upon selectionof a set of welding data, a section 734 of the dashboard screen 720 maydisplay graphical indicia (e.g., a score) associated with the selectedwelding data and/or at least a portion of the welding data. Moreover,details of the welding data 327 may be viewed upon selection of thewelding data 327 and a user control 736. The dashboard screen 720 mayenable the manager or instructor to save or edit the arrangement of thewelding data on the dashboard screen 720. Furthermore, the dashboardscreen 720 may enable the manager or instructor to export at least aportion of the welding data 327. For example, the manager may export thewelding data 327 corresponding to the sessions performed by a set ofoperators over the course of a day or a week. The dashboard screen 720may enable the manager or instructor to export the welding data 327 invarious formats, including but not limited to a comma-separated values(CSV) file, a spreadsheet file, and a text file. In some embodiments,the manager or instructor may remove a subset of welding data (e.g.,demonstration welding data) from the data storage system (e.g., cloudstorage system). Additionally, or in the alternative, the manager orinstructor may edit the welding data type 732, such as to revisetraining weld data as non-training weld data, revise the operatorassociated with welding data, revise the time associated with weldingdata, and so forth.

As may be appreciated, the dashboard screen 720 may enable the manageror instructor to monitor, compare, and analyze the welding dataassociated with one or more registration numbers 726. In someembodiments, the performance, experience, and historical data of weldingoperators may be compared across organizations or groups via theregistration numbers 726. In some embodiments, the dashboard screen 720may enable the manager or instructor to set goals or provide assignmentsto desired registration numbers 726. Furthermore, the manager orinstructor may monitor and adjust previously established goals. Thedashboard screen 720 may enable notes or comments regarding the weldingperformance associated with one or more registration numbers to beentered and stored with the welding data.

FIG. 54 illustrates an embodiment of the welding system 10 in thewelding environment 11 that may track the position and/or orientation ofthe welding torch 14 without utilizing the markers 474 on the weldingtorch 14 discussed above in FIGS. 30-32. The welding system 10 of FIG.54 may track the position and/or orientation of the welding torch 14prior to conducting a welding process. In some embodiments, the weldingsystem 10 of FIG. 54 may track the position and/or orientation of thewelding torch 14 during the welding process. One or more depth sensors750 are arranged at various positions in the welding environment 11,such as a first depth sensor 752 above the workpiece 82, a second depthsensor 754 integrated with the welding helmet 41 (e.g., helmet trainingsystem), or a third depth sensor 756 horizontal with the workpiece 82,or any combination thereof. Each depth sensor 750 may have an emitterconfigured to emit a visible pattern at a desired wavelength and acamera configured to monitor the visible pattern in the weldingenvironment 11. The visible pattern emitted by each depth sensor 750 maybe the same or different than the visible pattern emitted by other depthsensors 750. Moreover, the desired wavelength of the visible pattern foreach depth sensor 750 may be the same or different among the depthsensors 750. FIG. 54 illustrates respective emitted visible patternsfrom each depth sensor 750 with solid arrows, and FIG. 54 illustratesthe patterns reflected toward each depth sensor 750 with dashed arrows.The wavelength of the visible patterns may be within the infrared,visible, or ultraviolet spectrum (e.g., approximately 1 mm to 120 nm).The emitter of each depth sensor emits the respective visible patterninto the welding environment 11 onto the welding surface 88, theworkpiece 82, the welding torch 14, or the operator, or any combinationthereof. By observing the visible pattern reflected in the weldingenvironment 11, the computer 18 may track objects (e.g., welding torch14, operator) moving within the welding environment. Additionally, thecomputer 18 may identify the shape of the workpiece 82 or a weldingjoint path on the workpiece 82 based upon observations of the visiblepattern in the welding environment 11.

As may be appreciated, an arc 758 struck by the welding torch 14 withthe workpiece 82 emits electromagnetic radiation. The wavelengths andthe intensity of the emissions at each wavelength of the electromagneticradiation emitted by the arc may be based on a variety of factorsincluding, but not limited to, the workpiece material, the electrodematerial, the shielding gas composition, the weld voltage, the weldcurrent, the type of welding process (e.g., SMAW, MIG, TIG). In someembodiments, the sensing device 16 includes a light sensor configured todetect the wavelengths electromagnetic radiation of the weldingenvironment 11 prior to and during welding processes. The computer 18 ofthe welding system 10 may determine the emitted wavelengths and theintensity of the emitted wavelengths from the emitted based on feedbackreceived from the sensing device 16. Additionally, or in thealternative, the computer 18 may determine the emitted wavelengths andthe intensity of the emitted wavelengths from data stored in memory ofthe computer 18 or the data storage system 318, the welding parameters,and the arc parameters. For example, the computer 18 may determine thatthe arc for steel MIG welding has different predominant wavelengths thanthe arc for aluminum TIG welding.

In some embodiments, the wavelengths of the one or more visible patternsemitted by the depth sensors 750 may be selected to reduce noise fromthe arc 758 during welding processes. Furthermore, in some embodiments,the depth sensors 750 can vary the wavelength of the emitted visiblepattern. Accordingly, the computer 18 may adaptively control thewavelengths of the emitted visible patterns to improve the accuracy ofthe position and orientation determinations from the depth sensorfeedback. That is, the computer 18 may control the depth sensors 750 toemit the visible pattern in a first range for steel MIG welding, and toemit the visible pattern in a different second range for aluminum TIGwelding. Additionally, or in the alternative, the computer 18 may filterthe signals received by the depth sensors 750 to reduce or eliminate theeffects of the emissions by the arc 758.

Furthermore, the arc 758 may not be continuous during the weld formationfor some welding processes (e.g., short circuit MIG). The emittedelectromagnetic radiation when the arc 758 is out (e.g., during a shortcircuit phase of the welding process) may be substantially less than theemitted electromagnetic radiation when the arc 758 is live. The computer18 may control the depth sensors 750 to emit the respective visiblepatterns when the arc 758 is out (e.g., extinguished) rather than whenthe arc 758 is live, thereby enabling the depth sensors 750 to track theposition and/or orientation of the welding torch 14 during the weldprocess. That is, the computer 18 may synchronize the emitted visiblepatterns to substantially coincide with the short circuit phases of thewelding process. The short circuit frequency may be greater than 30 Hz,thereby enabling the computer 18 to determine the position and/or theorientation of the welding torch 14 in the welding environment 11 atapproximately 30 Hz or more.

Additionally, or in the alternative to the depth sensors 750, thewelding system 10 may utilize a local positioning system 762 todetermine the position of the welding torch 14 within the weldingenvironment 11. Beacons 764 of the local positioning system 762 arearranged at known locations about the welding environment and emitsignals 766 (e.g., ultrasonic, RF) received via one or more microphones429 on the welding torch. The computer 18 coupled to the one or moremicrophones 429 may determine the location of the welding torch 14within the welding environment 11 based at least in part on receivedsignals from three or more beacons 764. The computer may determine theposition of the welding torch 14 via triangulation, trilateration, ormultilateration. More than three beacons 764 of the local positioningsystem 762 distributed about the welding environment 11 increase therobustness of the local positioning system 762 and increase thelikelihood that the welding torch 14 is within a line of sight of atleast three beacons 764 at any point along a workpiece 82 having acomplex shape (e.g., pipe). In some embodiments, beacons 764 may bepositioned with depth sensors 750 or components of the welding system10, such as the welding power supply 28.

Returning to FIGS. 31 and 32, embodiments of the welding torch 14 mayhave multiple sets of visual markers 802 to facilitate detection of theposition and the orientation of the welding torch 14 relative to thetraining stand 12 and to the workpiece 82. In some embodiments, thesensing device 16 may detect and track multiple sets of visual markers802 at the same time (e.g., approximately simultaneously). However, thecontroller (e.g., computer 18) coupled to the sensing device 16 may onlystore or otherwise utilize tracking data related to one set of visualmarkers 802, such as the set of visual markers 802 that is the mostdirected towards the sensing device 16. As discussed herein, visualmarkers (e.g., LEDs 64) are considered to be directed towards a sensingdevice 16 that includes multiple cameras when the visual markers aredirected towards a fixed point in space with a known position relativeto each of the cameras of the sensing device 16. For example, where thesensing device 16 has multiple cameras arranged in an array, the fixedpoint may be a centroid of the multiple cameras. In some embodiments,the centroid is a central location relative to each camera of thesensing device, for example equidistant from the respective lenses ofthe cameras. In some embodiments, the visual markers 802 are LEDs 64that may be independently controlled. For example, each set (e.g., firstset 804, second set 806, third set 810) of LEDs 64 may be separatelycontrolled so that only one set is turned on and emits light at a time.In some embodiments, the visual markers 802 may be powered directly orindirectly via the weld cable coupled to the welding torch 14. Forexample, the visual markers 802 (e.g., LEDs 64) may receive power from apower port of the welding torch 14. Additionally, or in the alternative,an auxiliary cable bundled with or separate from the weld cable maypower the visual markers 802. Reducing the quantity of visual markers802 detectable by the sensing device 16 may reduce the complexity of thedetermination of the position and the orientation of the welding torch14. That is, the sensing device 16 may readily determine which side(e.g., top, left, right) of the welding torch 14 is facing the sensingdevice 16 based on the arrangement of the detected LEDs 64 when only oneset of LEDs 64 is turned on at a time. The control circuitry 52 of thewelding torch 14 may control the LEDs 64 so that at least one set of theLEDs 64 is detectable by the sensing device 16 during a simulated orlive welding session (e.g., live welding assignment). In someembodiments in which the welding torch 14 has at least one set ofpassive visual markers 802 (e.g., retroreflectors) oriented in a knowndirection, the control circuitry 52 such may control the LEDs 64 so thatnone of the sets of LEDs 64 are turned on when the passive visualmarkers 802 are detectable by the sensing device 16.

As may be appreciated, the arrangement of the visual markers 802relative to the welding torch 14 may be calibrated with the sensingdevice 16 so that the orientation direction (e.g., 784, 808, 812) ofeach set of visual markers 802 may be utilized to determine the positionand the orientation of the welding torch during live and/or training(e.g., simulated, augmented reality, virtual reality) weldingoperations. FIG. 77 illustrates a method 1100 that may be utilized tocalibrate the visual markers 802 (e.g., LEDs 64) of the welding torch14. Calibration markers (e.g., secondary visual markers) may be coupled(block 1102) to the welding torch, such as at the tip of the weldingtorch, such that the calibration markers are aligned with the axis 53 ofthe welding torch 14. The calibration markers may include, but are notlimited to two or more active or passive markers, similar to thecalibration tool 610 illustrated in FIGS. 44 and 45. The torch is placed(block 1104) in a holder (e.g., clamp, vice) such that the calibrationmarkers and a first set of visual markers 802 is viewable by the sensingdevice 16. Where the first viewable set of visual markers 802 has activemarkers (e.g., LEDs 64), the first set of visual markers 802 is turnedon (block 1106). The sensing device 16 detects (block 1108) thecalibration markers coupled to the torch and the first viewable set ofvisual markers 802. In some embodiments, the processor 20 coupled to thesensing device 16 determines (block 1110) the orientation of the weldingtorch 14 based on the detected calibration markers separate from thefirst viewable set of visual markers 802. For example, the processor 20may determine the orientation of the axis 53 of the welding torch 14 inthe known position based at least in part on known relationship betweenthe calibration markers coupled to the welding torch 14. In someembodiments, the processor may determine (block 1110) the orientation ofthe welding torch 14 in a similar manner as discussed above with themarkers 630, 632 of the calibration tool 610. In some embodiments, theprocessor 20 may determine (block 1112) the orientation of the first setof visual markers 802 relative to the determined orientation of thewelding torch 14. Additionally, or in the alternative, the processor 20may determine (block 1112) the orientation of the first set of visualmarkers 802 relative to a rigid body model of the first set of visualmarkers 802 based at least in part on a relative position of two or morevisual markers of the first set of visual markers 802. The first set ofvisual markers 802 is positioned on the welding torch 14, as describedabove with FIGS. 31 and 32, such that the arrangement detected by thesensing device 16 may be recognized by code executed by the processor 20to determine the corresponding rigid body model. Upon recognition of thearrangement of the first set of visual markers 802, the processor 20determines (block 1114) the orientations of the other sets of visualmarkers 802 based on the known geometric relationships between the setsof visual markers 802 of the welding torch 14. Moreover, the processor20 determines (block 1116) the orientation of the display 62 of thewelding torch 14 based on the known geometric relationships between thesets of visual markers 802 about the welding torch 14, recognition ofthe display 62 by the sensing device 16, recognition of a particularpattern (e.g., calibration pattern, manufacturer logo) of the display 62by the sensing device, or any combination thereof. Once the weldingtorch 14 and the sets of visual markers 802 coupled thereto arecalibrated, such as by the method 1100, the welding torch 14 may beutilized for live and/or training welding operations. Determination ofthe orientation of the display 62 relative to the axis 53 of the weldingtorch 14 and/or to the sets of visual markers 802 enables the graphicalrepresentations on the display 62 to correspond to the orientation ofthe display 62 to the joint.

The processor 20 coupled to the sensing device 16 and/or the controlcircuitry 52 may determine which set of LEDs 64 to turn on to track themovement and position of the welding torch 14 utilizing a method 860illustrated in FIG. 55. As may be appreciated, the method 860 may beperformed by a controller, which includes, but is not limited to theprocessor 20, the control circuitry 52, or a combination thereof.Generally, the controller may turn on each set of LEDs 64 sequentiallyfor a detection interval, then compare the response detected by thesensing device 16 from each set to determine which set of LEDs 64enables better tracking data. For example, the controller may turn on(block 862) the left set (e.g., second set 806) of LEDs 64. Thecontroller determines (node 864) whether the left set of LEDs 64 isdetected within the detection interval (e.g., approximately 50 to 500,100 to 300, or approximately 200 ms). If the left set of LEDs 64 is notdetected at node 864, the controller may turn on (block 866) the top set(e.g., first set 802) of LEDs 64. The controller then determines (node868) whether the top set of LEDs 64 is detected. If the top set of LEDs64 is not detected at node 868, the controller may turn on (block 870)the right set (e.g., third set 810) of LEDs 64. The controller thendetermines (node 872) whether the right set of LEDs 64 is detected. Ifthe right set of LEDs 64 is not detected at node 872, then thecontroller may return to the start of the method 860, and turn on (block862) the left set of LEDs 64. In some embodiments, the controller mayrepeat method 860 to turn on each set of LEDs 64 in sequence until atleast one set of LEDs 64 is detected during the detection interval.

As discussed herein, when the controller determines whether a set ofLEDs 64 is detected (e.g., nodes 864, 868, 872), the controller maydetermine whether the threshold quantity (e.g., three, four, five, ormore) of LEDs 64 for the respective set is detected. As discussed above,the threshold quantity may be less than or equal to the total quantityof visual markers (e.g., LEDs 64) of a respective set. In someembodiments, the controller is configured to determine a rigid body (RB)model of the welding torch 14 upon detection of the threshold quantityof LEDs 64. The controller determines (nodes 874) which rigid body modelcorresponding to tracked sets of LEDs 64 is the closest to an idealmodel. As may be appreciated, the ideal model may correspond to when aset of LEDs 64 is directed directly towards the sensing device 16 (e.g.,one or more cameras) within a predetermined range of angles (e.g.,approximately 20, 30, 45, or 60 degrees). Furthermore, each set of LEDs64 may have its own predetermined range of angles between the axis(e.g., direction 784 for the first set 804, direction 808 for the secondset 806, direction 812 for the third set 810) of the LEDs 64 and thesensing device 16 for which it is the most ideal, such as approximately45 degrees for the top set of LEDs 64 and approximately 30 degrees forthe left and right sets of LEDs 64. In some embodiments, the first set802 of LEDs 64 may approximate the ideal model when the Y-axis 784relative to the welding torch 14 is directed to the sensing device 16.If the determined rigid body model of the welding torch 14 correspondingto one set of LEDs 64 (e.g., second set 806) does not approximate theideal model, the controller may turn off the one set and turn on thenext set (e.g., first set 802) of LEDs 64 to determine if anapproximately ideal rigid body model may be detected with the next set.Additionally, or in the alternative, the controller may utilize thedetected non-ideal angle of one set (e.g., first set 804) of LEDs 64 andthe predetermined relative angles of the other sets (e.g., second set806, third set 810) of LEDs 64 to determine which set (e.g., third set810) of LEDs 64 corresponds closest to the ideal model, thereby enablingthe controller to turn on that set (e.g., third set 810) of LEDs 64directly without turning on other sets (e.g., second set 806). Thecontroller may be configured to latch to a set of turned on LEDs 64 whenthe determined rigid body model approximates the ideal model.

In some embodiments, a set of LEDs 64 may approximate the ideal modelwhen LEDs 64 are oriented within approximately 20 to 60 degrees orapproximately 30 to 50 degrees of the sensing device 16. The lightemitted from each LED 64 may be viewable from points withinapproximately 45, 60, 70, or 80 degrees or more of the axis of the LED64. However, while each LED 64 may be viewable by the sensing device 16(e.g., one or more cameras) within a relatively wide angle cone (e.g.,approximately 45 to 80 degrees), each LED 64 may have a half intensityangle where the beyond which the intensity of the viewable light fromthe LED 64 is less than half the intensity along the axis (e.g., 0degrees) of the LED 64. As discussed herein, an LED 64 or visual markeroriented toward the sensing device 16 (e.g., camera) is viewable by thesensing device 16. For example, a visual marker is oriented toward thesensing device 16 when the axis of the visual marker is unobscured andwithin approximately 80 degrees relative to a line of sight to thesensing device 16. Accordingly, based on the orientation of the sets ofLEDs 64, some embodiments of the controller may be able to determine arigid body model corresponding to more than one set of LEDs 64 at atime.

Where multiple rigid body models may be determined, the controller maydetermine which set of LEDs 64 is most oriented toward the sensingdevice 16. Moreover, the controller may utilize a hysteresis controlwhen the welding torch orientation fluctuates near an angles wheremultiple rigid body models may be determined for respective sets of LEDs64. As discussed above, the first set 802 of LEDs 64 may be orientedapproximately along the Y-axis 784, and the second set 806 of LEDs 64may be oriented so that the second direction 808 is offset approximately45 degrees from the Y-axis 784. In some embodiments, rigid body modelsmay be reliably determined for each respective set of LEDs 64 orientedwithin approximately 30° (e.g., half intensity angle) of the line ofsight to the sensing device 16, such that rigid body models for eachrespective set (e.g., 802, 806) may be determined for an overlappingrange of approximately 15° or more. As may be appreciated, otherarrangements of sets of LEDs 64 with different offsets relative to theY-axis 784 or different half intensity angles may have differentoverlapping ranges (e.g., approximately 5 to 45 degrees, 10 to 30degrees, or 15 to 25 degrees) between the sets of LEDs 64. Therefore,overlapping viewable ranges of the sets of LEDs 64 may reduce oreliminate positions (e.g., dead zones) of the welding torch 14 for whichat least one set of LEDs 64 is not detectable (e.g., viewable) by thesensing device 16. For example, the controller utilizing the hysteresiscontrol may remain latched to the first set 804 of LEDs 64 when thefirst set 804 is oriented within approximately 45 degrees of the line ofsight to the sensing device 16 even when the second set 806 is orientedwithin less than approximately 45 degrees of the line of sight to thesensing device 16. However, the hysteresis control may direct thecontroller to unlatch from the first set 804 of LEDs 64 and to latch tothe second set 806 when the first set 804 is oriented greater than alatch angle threshold (e.g., approximately 45 degrees) relative to theline of sight to the sensing device 16 and the second set 806 isoriented toward the line of sight to the sensing device 16 more than thefirst set 804. That is, the hysteresis control may reduce the turningoff and on sets of LEDs 64 when multiple sets of LEDs 64 may bedetectable by the sensing device 16 and prevents rapid oscillationbetween sets of LEDs 64 when the welding torch 14 is oriented near thethreshold between sets of LEDs 64 and/or is briefly oriented differentlyduring operation. The hysteresis control may direct the controller toremain latched to a set of visual markers 802 based on the orientationangle of the respective set of visual markers 802 relative to the latchangle threshold, the continuous duration that the respective set ofvisual markers 802 is oriented within the latch angle threshold, or anycombination thereof. Whereas the controller alone may latch to the firstset 802 of LEDs 64 when the first set 802 of LEDs 64 is directed withinthe half intensity angle of the set of LEDs 64, (e.g., approximately 30degrees), the hysteresis control directs the controller to remainlatched to the first set 802 of LEDs 64 for angles up to the latch anglethreshold that is greater than the half intensity angle, and to changeto the second set 806 of LEDs 64 when the first set 802 is oriented morethan the latch angle threshold and the second set 806 is oriented withinthe latch angle threshold. The latch angle threshold may include, but isnot limited to the half intensity angle (e.g., approximately 20, 30, 45,or 60 degrees) of the LEDs 64. Additionally, or in the alternative, thecontroller to remain latched to the first set 804 of visual markers 802while the axis 784 of the first set 804 is within a latch anglethreshold of approximately 10 to 60, 15 to 45, or 20 to 30 degreesrelative to a line of sight to the sensing device 16. The controller mayremain latched to the first set 804 despite brief intervals (e.g., lessthan approximately 10, 5, 3, or 1 seconds) for which first set 804 isstill visible yet the second set 806 of visual markers 802 is mostdirected towards the sensing device 16.

Upon latching to a set of LEDs 64 that approximate the ideal model, thecontroller may update (blocks 876) the items displayed on the display 32of the welding system 10, the display 32 of the helmet 41, and/or thedisplay 62 of the welding torch 14 based at least in part on theposition and orientation determined from the tracked set of LEDs 64. Insome embodiments, the controller may update (block 876) the displays 32and/or 62 in real time (RT), thereby enabling the guides of thegraphical representations of the welding parameters to be RT guidesusable by the operator during the welding operation. The controller maymaintain the status (e.g., on, off) of each set of LEDs 64 while thedetermined rigid body model approximates the ideal model. In someembodiments, the controller may repeat method 860 at intervals duringoperation, thereby turning on each set of LEDs 64 sequentially to verifythat the determined rigid body model of the latched set of LEDs 64 mostapproximates the ideal model. For example, the controller may repeatmethod 860 every 1, 5, or 15 minutes. Additionally, or in thealternative, the controller may repeat method 860 upon receipt of anassignment, selection of an assignment, upon lifting the welding torch14 from the training stand 12, or any combination thereof. As discussedherein, turning on each set of LEDs 64 sequentially may include aniterative sequence of turning on one set of LEDs 64 (e.g., first set804) of the welding torch 14 and turning off all other sets of LEDs 64(e.g., second set 806, third set 810) of the welding torch 14 for thedetection interval, such that each set of LEDs 64 is turned on and emitslight for a duration while the other sets of LEDs 64 are turned off anddo not emit light.

As discussed above, various elements of the welding system 10 may havemarkers for utilization to track movement of the respective elementwithin the welding environment in real-time and/or to calibrate theposition and orientation of the element relative to the training stand12 or to the workpiece 82. For example, the training stand 12 of FIG. 4may have the first and second markers 95, 96, the welding surface 112may have the markers 116, 118, the calibration tool 120 of FIG. 5 mayhave the markers 130, the fixture assembly 132 of FIG. 6 may have thefirst and second markers 134, 136, the welding torch 14 of FIG. 30 mayhave the markers 474, and the welding torch 14 of FIG. 31 may have thevisual markers 802. FIG. 56 illustrates a cross-sectional view of a basecomponent 880 that may be provided with visual markers 882. The basecomponent 880 may include, but is not limited to, the training stand 12,the workpiece 82, the welding surface 112, the calibration tool 120, thefixture assembly 132, the welding torch 14, the clamp assembly 588, orany combination thereof.

The base component 880 may be coupled to a thermally insulating layer884 (e.g., plastic, fabric, ceramic, resin, glass). In some embodiments,the base component 880 is thermally coated with the thermally insulatinglayer 884. Additionally, or in the alternative, the thermally insulatinglayer 884 may be wrapped about, molded to, mechanically fastened to,mechanically fastened around, or bonded to the base component 880. Asmay be appreciated, the base component 880 may receive or conductthermal heat from the welding process. In some embodiments, the basecomponent 880 is substantially (e.g., greater than 90 percent) coveredby the thermally insulating layer 884. The visual markers 882 may bepositioned at distinct locations on the insulating layer 884 of the basecomponent 880. In some embodiments, the visual markers 882 are at leastpartially embedded and/or recessed within the thermally insulating layer884. The visual markers 882 may be readily detectable by the sensingdevice 16. For example, the visual markers 882 may be reflective to oneor more electromagnetic waves. For example, the visual markers 882 mayreflect visible and/or infrared (IR) light. In some embodiments, one ormore of the visual markers 882 may emit light, such as via one or moreLEDs 64. The base component 880 may include a power source (e.g.,battery) coupled to such LEDs 64, or the LEDs 64 may be powered via apower cable coupled to the welding system 10 (e.g., via the computer18). The position of the each visual marker 882 may be configured toenable the sensing device 16 to determine the position and theorientation of the base component 880 within the welding environment.The visual markers 882 may be positioned on one or more faces of thebase component 880. The sensing device 16 may be configured to detectthe visual markers 882 and provide feedback to a controller (e.g.,computer 18) to determine a rigid body model of the base component 880and to determine a direction of a face of the base component 880 onwhich the detected visual markers 882 are disposed. That is, thecontroller (e.g., computer 18) may determine the rigid body model of thebase component 880 and the direction of the face of the base component880 in a similar manner as discussed above with determining rigid bodymodel of the sets of LEDs 64 coupled to the welding torch 14 anddetermining the respective marker directions of the sets of LEDs 64.Different quantities and/or arrangements of the visual markers 882 oneach side of the base component 880 may facilitate identification of therespective sides based on detection of the arrangement of the visualmarkers 882.

A cover layer 886 (e.g., cover plate) is coupled to the insulating layer884 and to the visual markers 882. The cover layer 886 may cover thevisual markers 882, thereby shielding the visual markers 882 from someenvironmental factors, such as spatter, dust, unintentional removal, andso forth. In some embodiments, the cover layer 886 does not cover oronly partially covers the visual markers 882. In some embodiments, thecover layer 86 is a plastic, such as polycarbonate. The cover layer 886may be a material that is not substantially reflective of one or moreelectromagnetic waves that are reflected by the markers 882.Additionally, or in the alternative, the cover layer 886 not covering avisual marker 882 may be conditioned to reduce or eliminate reflectionsof electromagnetic waves (e.g., visible light, infrared light). Forexample, the cover layer 886 may be painted, coated, or roughened (e.g.,sandblasted), or any combination thereof. In some embodiments, the coverlayer 886 is substantially non-reflective except in an area immediatelycovering the visual markers 882.

FIG. 57 is a perspective view of an embodiment of the welding stand 12,the arms 576, 578, and the clamp assembly 588. As discussed above, thefirst and second arms 576, 578 are rotatable about the support structure566 to enable the first and second arms 576, 578 to be positioned at aselected height for vertical and/or overhead welding. As illustrated,the second arm 578 includes a clamp assembly 588 for coupling theworkpiece 82 to the second arm 578. The second arm 578 and the clampassembly 588 may be positioned at various heights relative the trainingstand 12. Additionally, or in the alternative, the clamp assembly 588may be coupled to each arm 576, 578, and the clamp assembly 588 may beoriented in various directions relative to the sensing device 16. As maybe appreciated, the clamp assembly 588 may include multiple visualmarkers 802 markers (e.g., reflective and/or light emitting) tofacilitate tracking by the sensing device 16. For example, in certainembodiments, the clamp assembly 588 may include three markers on onesurface (e.g., in one plane) of a clamp body 889, and a fourth marker onanother surface (e.g., in a different plane) to facilitate tracking bythe sensing device 16. A clamp face 890 of the clamp body 889 may besubstantially parallel to the sensing device 16, or oriented at anoffset angle from the sensing device 16. A mount 892 couples the clampassembly 588 to the second arm 578.

FIG. 58 is a top view of an embodiment of the mount 892 of the clampassembly 588 of FIG. 57, taken along line 58-58. A clamp axle 900couples the mount 892 to the clamp body 889. In some embodiments, aretaining feature 902 of the clamp axle 900 may limit the movement ofthe clamp axle 900 along a clamp axis 904 in at least one direction.Furthermore, a clamp fastener 906 may interface with the retainingfeature 902 and the mount 892 to retain the clamp axle 900 in a desiredposition along the clamp axis 904. The mount 892 may rotate about anaxis 908, thereby adjusting the orientation of the clamp body 889 andthe clamp face 890 relative to the sensing device 16. In someembodiments, a fastener 910 (e.g., pin) may couple the mount 892 to thesecond arm 578 at a desired orientation. The fastener 910 may be fixedlycoupled to the mount 892, thereby preventing removal of the fastener 910from the welding system 10. In some embodiments, the retaining feature902 and/or the fastener 910 may be biased (e.g., spring loaded) withrespect to the clamp assembly 588, thereby enabling automatic engagementwith the clamp assembly 588 in one or more predetermined positions. Forexample, inserting the fastener 910 into a first recess 912 orients theclamp face 890 in a first direction 914 substantially parallel tosensing device 16, inserting the fastener 910 into a second recess 916orients the clamp face 890 in a second direction 918, and inserting thefastener 910 into a third recess 920 orients the clamp face 890 in athird direction 922. The second and third directions 918 and 922 may beoriented within approximately 10, 20, 30, 40, or 50 degrees of direction914 (e.g., towards the sensing device 16). The second and thirddirections 918 and 922 of FIG. 58 are approximately 30° offset from thefirst direction 914. When the clamp assembly 588 is mounted on thesecond arm 578 and the clamp face is oriented in the second direction918, the clamp assembly 588 may be configured for welding in positionsin which a portion of the workpiece 82 may obscure part of the jointfrom view of the sensing device 16. For example, welds performed in the3F position (e.g., vertical fillet welds of T and lap joints) may bereadily observed by the sensing device 16 when the workpiece 82 iscoupled to the clamp assembly 588 on the second arm 578 such that theclamp face 890 is oriented in the second direction 918.

The position and the orientation of the arms and respective clampassemblies are calibrated to enable the sensing device 16 to track themovement of the welding torch 14 relative to a joint of the workpiece 82coupled to the clamp assembly 588. As illustrated in FIG. 59, acalibration block 930 may be coupled to the clamp assembly 588 tofacilitate the calibration of the clamp assembly 588. In someembodiments, the calibration tool 610 of FIGS. 44 and 45 is coupled tothe calibration block 930 such that the calibration tool 610 extendsfrom the calibration block 930 at a predefined angle (e.g.,perpendicular). The calibration block 930 and the calibration tool 610may enable the sensing device 16 to calibrate the normal vector of theclamp assembly 588, to calibrate the normal vector of workpieces 82secured to the clamp assembly 588, and/or to calibrate the true vertical(i.e., zenith) vector relative to the floor. The sensing device 16, viathe computer 18, may determine a rigid body model and/or a centroid ofclamp markers for the clamp assembly 588 when mounted to each arm 576,578, during which different sides of the clamp assembly 588 are in viewof the sensing device 16 where each side of the clamp assembly 588 has aunique configuration of markers. The sensing device 16 may be coupled tothe arms 576, 578 so that as each arm is raised and lowered, a y-valueof a centroid of the clamp markers of the respective side changes. Asdiscussed above, movement of each arm 576, 578 may adjust theorientation of the sensing device 16. Accordingly the sensing device 16may determine the y-value of the centroid of clamp markers for the clampassembly 588 at multiple heights of the respective arms 576, 578. Thecomputer 18 may determine the zenith vector for each of the centroids atthe respective heights, thereby enabling the computer 18 to determine(e.g., interpolate) the zenith vector for any height using the y-valueof the centroid of clamp markers when the clamp assembly 588 is coupledto each arm 576, 578. A level may be utilized with the clamp calibrationblock 930 during calibration at each height to ensure the orientation ofcalibration tool 610 accurately represents the zenith vector. They-value of the centroid of clamp markers can also be used to determinethe height of the clamp and to provide the operator with feedback oncorrect height positioning for welding session. The height of the clampassembly 588 during a welding session may be stored with the weldingdata 327 for each welding session. In some embodiments, the weldingsystem 10 may determine the orientation of the clamp assembly 588relative to the sensing device 16, thereby enabling the welding system10 to notify the operator if the workpiece 82 is in an improperorientation for the welding session. For example, the welding system 10may notify the operator when the clamp assembly 588 and workpiece 82 areoriented such that the visual markers 802 of the welding torch 14 wouldbe at least partially obscured from view of the sensing device 16 duringthe welding session, thereby enabling the operator to adjust the clampassembly 588 so that all of the visual markers 802 may be observed.

FIG. 60 is a flowchart 940 that illustrates the set up and execution ofassignment welding session utilizing one of the arms for a vertical oroverhead (e.g., out of position) session. The operator selects (block942) an out of position session (e.g., 2G, 3G, 3F, 4G, 4F) and tacks(block 944) the workpiece together. The operator then sets up (block946) the desired arm to the height corresponding to the session andadjusts the clamp assembly for calibration with the sensing device. Uponsetup of the arm and clamp assembly, the operator couples (block 948)the workpiece to the clamp assembly. Then the operator may adjust (block950) the clamp orientation, such as if the workpiece at least partiallyobscures the joint from the sensing device, if markers of the workpieceor clamp assembly are obscured from the sensing device, or if the clampassembly is not substantially perpendicular to the ground, or anycombination thereof. After adjusting the clamp orientation, theoperator, an instructor, or an administrator may calibrate (block 952)the clamp assembly. In some embodiments, the calibration may beperformed once for each occasion that the arm is moved or for eachoccasion that the clamp assembly is attached to the arm, such that theclamp assembly may not calibrated prior to each session. The calibrationof the clamp assembly may validate that the clamp assembly is detectedin the configuration and/or orientation specified for the session. Theoperator calibrates (block 954) the joint ends, thereby establishing the2 points in a line representing the joint. In some embodiments, such asfor welding sessions in the 3F position, the operator calibrates (block954) the joint ends utilizing the calibration tool 610 described abovewith FIGS. 44 and 45, where an axis of the calibration tool is heldwithin approximately 5° of parallel to the sensing device. As may beappreciated, welding sessions in other positions may be calibrated withthe calibration tool having other orientations relative to the sensingdevice. Additionally, or in the alternative, the computer may compensatefor orientations of the calibration tool during calibrations where themarkers of the calibration tool are observed at a skewed angle. Forexample, the computer may determine the angle of the calibration toolrelative to the clamp assembly, then utilize the determined angle toadjust calibration values of the joint ends. After the calibration ofthe joint ends, then the operator performs (block 956) the weldingsession and reviews (block 958) the results. In some embodiments, thedisplay of the training stand and/or the display of the welding torchmay provide instructions to the operator to guide the setup for thewelding session.

The sensing device 16 may track the position and orientation of theclamp assembly 588, the workpiece 82, and the welding torch 14 prior toperforming assignment welding session, during the welding session, andafter performing the welding session. As discussed above, the sensingdevice 16 may include one or more cameras that detects visual markers802, such as visual markers of the clamp assembly 588, the workpiece 82,and the welding torch 14. In some embodiments, the computer 18 mayutilize data corresponding to the visual markers 802 of fixed surfaces(e.g., the clamp assembly 588, the workpiece 82) for reference withrespect to other tracked objects in the welding environment whenever thevisual markers 802 of the fixed surfaces are detectable. That is, thevisual markers 802 of the fixed surfaces facilitate real-time trackingof other objects (e.g., welding torch 14, calibration tool 610) withinthe welding environment. The visual markers 802 detected by the one ormore cameras of the sensing device 16 may include passive markers (e.g.,stickers, reflectors, patterns) and/or active markers (e.g., lights,LEDs). The passive markers may be best observed with a first exposuresetting (e.g., 8, 15, 25, 50) of the one or more cameras of the sensingdevice 16, and the active markers may be best observed with a secondexposure setting (e.g., 1, 2, 3, 4, 5) of the one or more cameras, whichmay be different than the first exposure setting. In some embodiments,the visual markers 802 of the clamp assembly 588 and the workpiece 82may be passive markers, and the visual markers 802 of the welding torch14 may be active markers (e.g., LEDs 64). Moreover, the passive markersmay be illuminated by a light source (e.g., one or more lights, LEDs 64)of the sensing device 16, where light (e.g., infrared light, visiblelight) from the light source reflects off the passive markers and isobserved by one or more cameras of the sensing device 16 when thepassive markers are oriented towards the one or more cameras.Accordingly, the exposure setting of the one or more cameras may beadjusted based at least in part on the type of visual marker to beobserved. As may be appreciated, the second exposure setting forsampling the active markers that emit light may be less than the firstexposure setting for sampling the passive markers that reflect light.

The computer 18 may alternately track the visual markers 802 of thewelding torch 14 and the fixed surfaces of the welding environment priorto performing and during performance of a welding session (e.g.,simulated welding assignment, live welding assignment). Accordingly, thecomputer 18 may track in real-time the position and the orientation ofthe welding torch 14, the clamp assembly 588, and the workpiece 82relative to each other and to the training stand 12. The computer 18 mayprimarily track the visual markers 802 of welding torch 14 whendetecting the position and orientation of objects in the weldingenvironment about the training stand 12, and the computer 18 maysecondarily track the visual markers 802 of the fixed surfaces (e.g.,main welding surface 88, clamp assembly 588, clamped workpiece 82). Thatis, the computer 18 may primarily track the visual markers 802 of thewelding torch 14 by sampling to detect the active visual markers 802 ofthe welding torch 14 at a higher rate than the secondarily trackedpassive visual markers on the fixed surfaces. The active markers of thewelding torch 14 may be turned on substantially continuously before,during, and after a simulated or live welding session (e.g., weldingassignment). The computer 18 may control the exposure setting of the oneor more cameras of the sensing device 16 to control the respectivesampling rates of the fixed surfaces and the welding torch 14. Forexample, the visual markers 802 of the welding torch 14 may be sampled1.5, 2, 3, 4, 5, or more times than the visual markers 802 of the fixedsurfaces are sampled. Additionally, or in the alternative, an activevisual marker sample interval may be greater than a reflective visualmarker interval, where the computer 18 repeatedly tracks visual markersof the welding system 10 by cycling through the active visual markersample interval and the reflective visual marker sample interval. Thatis, the computer 18 cycles the exposure setting of the one or morecameras between the second exposure setting (e.g., low exposure value totrack the active markers of the welding torch 14) and the first exposuresetting (e.g., high exposure value to track the passive markers of thefixed surfaces). Adjusting the exposure setting of the one or morecameras of the sensing device 16 may lag the cycling of sampleintervals. In some embodiments, the computer 18 may record datacorresponding to detected passive (e.g., reflective) visual markersregardless of which sample interval (e.g., reflective visual markerinterval, active visual marker sample interval) during which the data isreceived. Moreover, the computer 18 may record data corresponding todetected active visual markers only when passive visual markers are notdetected, thereby improving the accuracy of the recorded data byreducing noise that may be associated with detecting multiple types(e.g., active, passive) of visual markers.

Prior to initiating a simulated welding session (e.g., weldingassignment), the computer 18 may control the light source of the sensingdevice 16 (e.g., LEDs 64) to be turned on, thereby enabling the computer18 to track the passive markers of the fixed surface and the activemarkers of the welding torch 14 prior to initiating the simulatedwelding session, during the simulated welding session, and after thesimulated welding session. As described above, the computer 18 may cyclethe exposure setting of the one or more cameras prior to initiating andduring the welding assignment to sample the passive markers with thefirst exposure setting and to sample the active markers with the secondexposure setting. During live welding (e.g., while the trigger of thewelding torch 14 is actuated), the computer 18 may control the lightsource of the sensing device 16 to pulse at an increased brightnesslevel, thereby cyclically increasing the reflected light from thepassive markers. Pulsing (e.g., strobing) the light source may enablethe one or more cameras of the sensing device 16 to readily track thepassive markers with a reduced exposure setting during live welding withthe bright arc and spatter. Furthermore, pulsing the light sourceilluminating the passive markers may reduce motion blur. The computer 18may control the exposure setting of the one or more cameras to besynchronized with the pulsing of the light source of the sensing device16, such that the light source pulses more brightly when the exposuresetting is at the first (e.g., high) exposure setting, and the lightsource dims or turn off when the exposure setting is at the second(e.g., low) exposure setting. For example, the computer 18 may controlthe exposure setting of the one or more cameras so that the exposuresetting is set at the first (e.g., high) exposure setting to detect thepassive markers when the light source pulses brightly, and the exposuresetting is set at the second (e.g., low) exposure setting to detect theactive markers when the light source dims or turns off Additionally, orin the alternative, the computer 18 may control the light source of thesensing device 16 to turn off during calibration of the clamp assembly588, thereby distinguishing the active markers of the welding torch 14from the passive markers of the clamp assembly 588. In some embodiments,a pulsed brightness level of the light source of the sensing device 16may be greater than when the light source is turned on substantiallycontinuously (e.g., prior to and after completion of a weldingassignment while the weld system records data related to the weldingassignment). The sensing device 16 may more readily detect the passivemarkers at the greater brightness level of the light source than at thelower brightness level. However, pulsing (e.g., strobing) the lightsource of the sensing device 16 during non-live welding operations(e.g., a simulated weld, virtual reality weld) may unintentionallyactivate an auto-darkening circuit of a welding helmet. Accordingly, thelight source of the sensing device 16 may be pulsed during live weldingwhen the welding helmet is darkened due to the arc, yet the light sourceof the sensing device 16 is turned continuously on during simulatedwelding when the welding helmet is not darkened. The computer 18 maycontrol the pulse rate and/or the pulse duty cycle (e.g., 10%, 25%, 50%,100%) of the light source (e.g., one or more LEDs 64). Additionally, orin the alternative, the computer 18 may control illumination settings(e.g., wavelength, intensity) of the light source of the sensing device16 during non-live welding intervals so that the auto-darkening circuitof a welding helmet does not activate. For example, where theauto-darkening circuit of a welding helmet activates in response tolight of a certain wavelength or intensity, the computer 18 may controlthe light source to pulse or continuously emit light of a wavelength orintensity that reduces or eliminates the activation of theauto-darkening circuit.

In some embodiments, the welding system 10 may track a multi-pass (e.g.,multi-run) session, thereby recording welding data 327 for each pass(e.g., run) of the multi-pass session. As discussed above with FIG. 40,the control circuitry 52 of the welding system 10 may record the weldingdata 327 for each run of the multi-run session as a single weldingoperation for determining a quality of the multi-run session or forotherwise reviewing the multi-run session. In some embodiments, thecontrol circuitry 52 of the welding system 10 may record welding data327 for a multi-run session as a group of runs that correspond to aserial number or other identifier for the multi-run session.

That is, the welding data 327 for a multi-run session may be reviewedand evaluated as a group, or each run of the multi-run session may bereviewed and evaluated separately. Multi-run sessions may include, butare not limited to a live process, a simulated process, a virtualreality process, or any combination thereof.

FIG. 61 is a flowchart 970 that illustrates the selection and executionof a multi-pass (e.g., multi-run) welding session (e.g., weldingassignment). The operator selects (block 972) a multi-run session andsets up (block 974) the workpiece 82 together on the training stand 12.Set up of the workpiece 82 may include clamping the workpiece 82 to thetraining stand 12. The operator calibrates (block 976) the joint, suchas by utilizing the joint calibration tool 610 to calibrate the positionof a first end of the joint and the second end of the joint. As may beappreciated, the joint calibration tool 610 may directly interface withthe workpiece 82 for the calibration (block 976) prior to the first runof the multi-run session. The operator selects (node 978) whether toperform the next (i.e., first) run of the multi-run session in asimulated welding mode or a live welding mode. In some embodiments, theselected welding session (e.g., welding assignment) may prohibit orlimit the quantity of simulated welds that may be performed prior tolive welds. In some embodiments, the selected session may prohibit thelive welding mode until completion (e.g., satisfactory completion) of asimulated weld. As discussed herein with FIG. 61, a simulated weldingmode is distinct from the live welding mode, and the simulated mode mayinclude, but is not limited to, the simulated mode, the virtual realitymode, or the augmented reality mode. When the simulated weld mode isselected, the operator performs (block 980) the simulated run. Thecontrol circuitry 52 may display (block 982) the results of thesimulated run via the display 32 of the training stand 12, the display62 of the welding torch 14, or the display 32 of the weld helmet 41. Forexample, the control circuitry 52 may display the weld data 327 from thesimulated run and the target specifications for the simulated run.Additionally, or in the alternative, the control circuitry may displaythe weld score for the simulated run. After completing the simulatedrun, the operator again selects (nodes 978) whether to perform the nextrun in the simulated welding mode or in the live welding mode.

When the live welding mode is selected, the operator performs (block984) the live weld run on the calibrated joint. The control circuitry 52may display (block 986) the results of the live run via the display 32of the training stand 12 and/or the display 62 of the welding torch 14.For example, the control circuitry 52 may display the weld data 327 fromthe live run and the target specifications for the live run.Additionally, or in the alternative, the control circuitry 52 maydisplay the weld score for the live run. The displayed results for thelive run may be displayed with results of any previous simulated runsfor the same joint.

Each run (e.g., simulated or live) of the multi-run welding session(e.g., welding assignment) may be evaluated separately based at least inpart on target specifications (e.g., minimum, goal, maximum) for torchposition parameters (e.g., work angle, travel angle, CTWD, travel speed,aim) and/or electrical parameters (e.g., weld voltage, weld current,wire feed speed). For example, a rootpass run may have differentspecification parameters than subsequent runs. After a run of themulti-run session is completed, the control circuitry 52 may determinewhether the completed run of the session satisfies the target parametervalues for the respective run. For example, the welding data 327 for arun of the multi-run session may be compared with the target parametervalues to generate a score for each parameter and/or a total score forthe respective run. The control circuitry 52 may determine whether therun passes the target specifications for the respective run.

The control circuitry 52 determines (node 988) whether all of the runsof the selected welding session (e.g., welding assignment) have beencompleted. If all of the runs of the selected multi-run session have notbeen completed, then the operator selects (block 990) the next run. Insome embodiments, the operator may proceed to the next run of themulti-run session regardless of whether the previous run passes thetarget specifications. Additionally, or in the alternative, the operatormay proceed to the next run of the multi-run session regardless ofwhether the weld data 327 for the previous run is complete. For example,if the sensing device 16 cannot track the position and the orientationof the welding torch 14 for at least a portion of a run of the multi-runsession, the operator may continue performing each run of the multi-runsession. The operator calibrates (block 976) the joint for each run of amulti-run session, such as by utilizing the joint calibration tool 610to calibrate the position of a first end of the joint and the second endof the joint. As may be appreciated, joint calibration tool 610 may havedirectly interfaced with the workpiece 82 for the initial calibration ofthe joint prior to the first run. Subsequent calibrations may directlyinterface the joint calibration tool 610 with the previously formed weldbead of one or more previous runs. Accordingly, the calibrated ends ofthe joint for each run may have a different position relative to thesensing device 16 of the welding system 10. When the subsequentcalibration for the next run is completed, the operator again selects(nodes 978) whether to perform the next run in the simulated weldingmode or in the live welding mode.

If all of the runs of the selected multi-run session have beencompleted, then the control circuitry 52 may display (block 992) theresults of each of the live runs via the display 32 of the trainingstand 12 and/or the display of the welding torch 14. For example, thecontrol circuitry 52 may display the weld data 327 from each of the liveruns and the target specifications for each of the live runs.Additionally, or in the alternative, the control circuitry 52 maydetermine whether the group of runs passes the target specifications forthe multi-run session based on one or more evaluations of the runs. Forexample, the control circuitry 52 may evaluate the group of runs with atotal score based on a geometric mean of the scores for each run, anarithmetic mean of the scores for each run, a minimum score of the groupof runs, a sum of the determined scores, whether each run was completedwith a passing score, or any combination thereof. In some embodiments,ending the welding session with fewer completed live runs than specifiedfor the multi-run welding session may result in an inadequate (e.g.,failing) total score for the multi-welding run session. In someembodiments, a threshold quantity (e.g., 1, 2, or 3) of runs withuntracked welding torch position and orientation may not affect theevaluation of the multi-run session. That is, the one or more runs withuntracked welding torch position and orientation may not be counted inthe geometric and/or arithmetic mean. In some embodiments, the controlcircuitry 52 may store the weld data 327 from each run of the multi-runsession locally until completion of the multi-run session. Uponcompletion, the control circuitry 52 may transmit the weld data 327associated with the completed multi-run session to a remotely locateddata storage system 318. Upon display of the session results (block992), the operator may select (block 994) to retest with the selectedsession. The operator removes the previously tested joint, and sets up(block 974) a new joint for the retest. The control circuitry 52 mayassign a different serial number to the new joint for the retest thanthe serial number of the previously tested joint, thereby enabling theoperator and an instructor to review and evaluate the weld data 327 fromeach joint.

As described herein, various parameters may be tracked (e.g., detected,displayed, and stored) during operation of the welding system 10 (e.g.,in real-time while the welding system 10 is being used) including, butnot limited to, torch position parameters (e.g., work angle, travelangle, CTWD, travel speed, aim) and arc parameters (e.g., weld voltage,weld current, wire feed speed). The arc parameters, for example, may bedetected in the welding torch 14 (e.g., using the voltage sensor 425,the current sensor 427, or other sensors, as illustrated in FIG. 25),converted using analog-to-digital conversion (ADC) circuitry, andcommunicated to the computer 18 via a communication interface 68 (e.g.,RS-232 communication channel), as discussed herein with respect toFIG. 1. Alternatively to, or in addition to, being detected in thewelding torch 14 (e.g., in the handle of the welding torch 14illustrated in FIG. 5), the arc parameters may be detected in the weldcable 80, the welding power supply 28, the wire feeder 30, or somecombination thereof, each of which are illustrated in FIG. 2.

The welding system 10 may detect and display (e.g., numerically,graphically, and so forth) the arc parameters via a screen viewable onthe display 32 of the welding system 10 similar to the screensillustrated in FIGS. 20 and 21, for example. An exemplary screen 996having a weld mode indicator 998 that indicates that the welding system10 is in a live-arc weld mode may be displayed on the display 32 isillustrated in FIG. 62. As illustrated in FIG. 62, the arc parametersmay be displayed on the screen 996. For example, in the illustratedscreen 996, a voltage graph 340 may display a time series of voltage 337of the arc produced by the welding torch 14, and an amperage graph 340may display a time series of the current 338 produced by the weldingtorch 14. In certain embodiments, filters may be applied to at leastsome of the arc parameters and the torch position parameters to smoothout noise in the time series graphs 340 of the values detected by thewelding torch 14.

It will be appreciated that the arc parameters may be time synchronizedby the welding software 244 in real-time with the torch positionparameters that is captured through the motion tracking system (e.g.,the sensing device 16). In other words, the arc parameters and the torchposition parameters may all be graphed on their respective graphs 340such that data points for each of the time series are vertically alignedwith data points from each of the other time series that are captured atapproximately the same time (e.g., within 100 milliseconds, within 10milliseconds, or even closer in time, in certain embodiments). Thisenables the user to correlate the arc parameters with the torch positionparameters. Although not illustrated in FIG. 62, in certain embodiments,wire feed speed may also be detected in real-time in the same manner asvoltage and current.

As illustrated in FIG. 62, in certain embodiments, each arc parameter(as well as each torch position parameter) may be individually scored inrelation to a pre-defined upper limit, lower limit, and/or target value,and the scores 341 may be depicted on the screen 996. In addition, incertain embodiments, a total score 1000 may be determined by the weldingsoftware 244 and depicted on the screen 996. In addition, in certainembodiments, the total score 1000, indications of target total scores1002 and high total scores 1004 (for example, of an entire class) may bedetermined by the welding software 244 and depicted on the screen 996.In addition, in certain embodiments, an indication 1006 of whether thetest was successful or not successful may also be determined by thewelding software 244 and depicted on the screen 996. In certainembodiments, the total score 1000 may be based on the individual scores341 for the torch position parameters, but not based on the individualscores 341 for the arc parameters.

In addition, as illustrated in FIG. 62, in certain embodiments, anoverall status bar 1008 may be depicted on the screen 996. The overallstatus bar 1008 may include indications of whether all of the torchposition parameters are within their respective upper and lower limitsor not. For example, if one of the torch position parameters are notwithin their respective upper and lower limits, the overall status bar1008 may indicate, at the same vertical position on the screen 996 asthe corresponding torch position parameter values, a red status.Conversely, if all of the torch position parameters are within theirrespective upper and lower limits, the overall status bar 1008 mayindicate, at the same vertical position on the screen 996 as thecorresponding torch position parameter values, a green status. It willbe appreciated that other status colors may be used in otherembodiments.

As illustrated, in certain embodiments, the value 339 for each of theparameters (e.g., the torch position parameters and the arc parameters)may be displayed as an average value over the course of a test period.For example, as illustrated in FIG. 62, the average voltage and amperageover the test period depicted are 18.7 volts and 146 amps, respectively.FIG. 63 is another illustration of the screen 996 depicted in FIG. 62.In this instance, the average voltage and amperage is depicted as being0.1 volts and 2 amps, respectively, which are on the order of noise,indicating that an actual welding arc is not being detected. In such asituation, the amperage and voltage can be used by the welding software244 to determine whether or not welding took place during a given “weldmode” test period. If the value of either voltage or amperage is below acertain predetermined threshold (e.g., the average voltage is less than10 volts) or between a certain predetermined minimum and maximumthreshold (e.g., the average voltage is between −8 volts and +10 volts),the welding software 244 may determine that a weld actually did not takeplace during the time period. In such a scenario, the welding software244 may automatically mark a test as failed (or “unsuccessful”) and/orthe test may be flagged by the welding software 244 as having no weldingdetected. For example, as illustrated, in certain embodiments, if theaverage voltage and/or the average amperage for a given test period donot meet certain predetermined threshold(s) or fall within certainpredetermined range(s), the indication 1006 of whether the test wassuccessful or not successful may depict that the test was “Unsuccessful”(which may also be displayed for other reasons, such as the total scoredoes not meet a specific requirement, for example). In addition, as alsoillustrated, in certain embodiments, when the average voltage and/or theaverage amperage for a given test period do not meet certainpredetermined threshold(s) or fall within certain predeterminedrange(s), instead of depicting the total score 1000 on the screen 996,an “Arc Not Detected” message 1010 may be depicted instead.

FIG. 64 illustrates an exemplary screen 1012 that may be displayed aspart of the assignment development routines of the welding software 244.In particular, FIG. 64 illustrates a screen 1012 that enables input ofcompletion criteria for a series of weld tests and length requirementsassociated with the testing. As illustrated, the screen 1012 isdisplayed when the Completion Criteria/Length Requirements tab 1014 ofthe assignment development routines is selected (and, therefore,highlighted on screen 1012). As illustrated, other tabs associated withconfiguration settings of the assignment development routines of thewelding software 244 may include, but are not limited to, an AssignmentName tab 1016 that causes a screen to be displayed where the assignmentname and other general information relating to the assignment may beentered; a Joint Design tab 1018 that causes a screen to be displayedwhere properties of the joint to be welded upon (e.g., type of joint,length, etc.) may be entered; a Base Metals tab 1020 that causes ascreen to be displayed where properties related to the base metals to bewelded upon may be entered; a Filler Metals/Shielding tab 1022 thatcauses a screen to be displayed where properties relating to the fillermetals (e.g., of the welding electrode) and shielding gas(es) may beentered; a Position/Electrical Char. tab 1024 that causes a screen to bedisplayed where properties (e.g., upper limits, lower limits, targetvalues, etc.) of the torch position parameters and the arc parameters,respectively, may be entered; a Preheat/Postweld Heat Tr. tab 1026 thatcauses a screen to be displayed where properties relating to preheatingand postweld heating, respectively, may be entered; a WeldingProcedure/1 Pass tab 1028 that causes a screen to be displayed whereproperties relating to the welding procedure (e.g., process type, etc.)and the number of passes in the test (e.g., one pass or more than onepass); and a Real-Time Feedback tab 1030 that causes a screen to bedisplayed where properties relating to real-time feedback may beentered. It will be appreciated that, in certain embodiments, all of theproperties relating to an assignment may be entered on the describedscreens, may be automatically detected by the welding software 244(e.g., based on specific equipment of the welding system 10, based onother properties that are set, and so forth), or some combinationthereof.

As illustrated in FIG. 64, the screen 1012 relating to the CompletionCriteria/Length Requirements tab 1014 includes a first section 1032specifically dedicated to the completion criteria properties and asecond section 1034 specifically dedicated to length requirementsassociated with the testing. In certain embodiments, in the completioncriteria section 1032 of the screen 1012, a series of inputs 1036enables a target score (e.g., 90 as illustrated), a number of weld tasksin a set of weld tasks (e.g., 5 as illustrated), a number of successfulweld test required per weld set (e.g., 3 as illustrated), and whether aweld test will be failed if an arc is not detected (e.g., as shown inFIG. 63) to be entered. In addition, as illustrated, in certainembodiments, a depiction 1038 of what these selections of completioncriteria will look like to the user (e.g., as illustrated in FIG. 62 inthe Actions section 1040 of the screen 996). In addition, in certainembodiments, in the length requirements section 1034 of the screen 1012,a series of inputs 1042 enables a length of a start section (A) of aweld that will be ignored in the score compilations, an end section (B)of a weld that will be ignored in the score compilations, and a maximumlength (C) of the test, which may be less than the coupon length (whichmay, for example, be entered via the screen relating to the Joint Designtab 1018) to be entered. In addition, in certain embodiments, respectiveillustrations 1044 of relative dimensions of the entered propertiesrelating to the length requirements may also be depicted to aid the userin setting the length requirements.

FIG. 65 illustrates an exemplary screen 1046 that may be displayed whenthe Welding Procedure/1 Pass tab 1028 is selected. As described above,this screen 1046 enables properties relating to the welding procedureand the number of passes in the test (e.g., one pass or more than onepass) to be entered. As illustrated, in certain embodiments, a firstseries of inputs 1048 enables a process type (e.g., FCAW-G asillustrated), a class and diameter of the filler metals (e.g., thewelding electrode) (e.g., E71T-8JD H8 and 0.072 inches, respectively, asillustrated), a weld pattern (e.g., stringer vs. weave; stringer asillustrated), a vertical progression (e.g., up vs. down; up asillustrated), and any comments related to the welding procedure to beentered. In addition, as illustrated, in certain embodiments, a secondseries of inputs 1050 enables minimum, target, and maximum values forthe arc parameters (e.g., volts, wirefeed speed, and amps), labeled asWelding Power Source Settings, and the torch position parameters (e.g.,work angle, travel angle, CTWD, travel speed, and aim), labeled as TorchTechnique Parameters, to be entered. Also as illustrated, in certainembodiments, a third series of inputs 1052 enable more detailed inputrelating to minimum, target, and maximum values (e.g., relating to howmuch deviation from target values are allowed for the upper and lowerlimits, and so forth) for a highlighted arc parameter or torch positionparameter (e.g., volts as illustrated). In certain embodiments, whenmore than one pass is selected for a given assignment, the minimum,target, and maximum values for the arc parameters and/or the torchposition parameters may be individually set for each pass within theassignment. In certain embodiments, entry of properties for multiplepasses for a given assignment may be enabled via an Add Pass button1054, as illustrated.

As discussed above with respect to FIGS. 62 and 63, the arc parametersmay be displayed when the welding software 244 is in a live-arc weldmode. Conversely, FIG. 66 illustrates an exemplary screen 1056 thatdepicts the welding software 244 when in a simulated weld mode, asindicated by the weld mode indicator 998. As illustrated, when thewelding software 244 is in a simulated weld mode, the arc parameters arenot displayed since actual welding is disabled in this mode, and amessage indicating as much may be displayed instead.

In certain embodiments, the arc parameters are not displayed by defaultbelow the torch position parameters, such as illustrated in FIGS. 62 and63. Rather, FIG. 67 illustrates an exemplary screen 1058 that isdepicted by default (i.e., before a weld test has been initiated). Asillustrated, instead of the arc parameters, a welding procedure summarypane 1060 is illustrated to summarize for the user what the overallproperties (e.g., target properties) for a given test weld are. Incertain embodiments, from the welding procedure summary pane 1060, auser may select a View WPS button 1062, which will cause the screen 1064illustrated in FIG. 68 to be displayed. As illustrated, FIG. 68 is asummary of all of the information relating to all of the parameters of aweld test session or a weld test assignment (e.g., which may be enteredvia selection of the various assignment development tabs 1014-1030illustrated in FIGS. 64 and 65).

Returning now to FIG. 67, once the user has completed pre-testprocedures and is prepared to begin a weld test, upon activation of thetrigger 70 of the welding torch 14 to start a weld test, the weldingprocedure summary pane 1060 is replaced by the information relating tothe arc parameters to display the real-time graphing of the arcparameters during performance of the weld test (see, e.g., FIG. 69),allowing the user to view all graphs relating to the torch positionparameters and the arc parameters in real-time during the weld test.Indeed, in certain embodiments, upon activation of the trigger 70 of thewelding torch 14 to start a weld test, whatever screen is currentlybeing displayed may be replaced with, for example, the screen 996illustrated in FIG. 69 such that all of the torch position parametersand arc parameters may be graphically displayed in real-time.

FIG. 70 illustrates an alternative screen 1066 that may be displayedfollowing the performance of a test weld. As illustrated, in certainembodiments, in addition to the arc parameters (e.g., voltage, amperage,wire feed speed), heat input 1068 may be displayed and, as with all ofthe other torch position parameters and the arc parameters, is timesynchronized along their respective time series. In general, thedetected voltage and amperage data and the detected travel speed datamay be used to compute the heat input in real-time for each point intime along the time series (e.g., time-based) or at each location alongthe weld joint (e.g., distance-based). In particular, in certainembodiments, the heat input (in kilojoules) may be calculated as afunction of the voltage, the amperage, and the travel speed (in inchedper minute) as:

${HeatInput} = \frac{{Amps} \times {Volts} \times 60}{1000 \times {TravelSpeed}}$

In addition, although not illustrated in FIG. 70, in certainembodiments, the weld size (fillet size; in millimeters) can be computedin real-time using the wire feed speed (WFS; in inches per minute),which may either be detected or specified by a user, travel speed (inmeters per minute), and a predetermined value for efficiency (%), andwire diameter (in millimeters) as:

${FilletSize} = \sqrt{\frac{\left( {\frac{\pi}{4} \times {WireDiameter}^{2}} \right) \times \left( {25.4 \times {WFS}} \right) \times {Efficiency}}{\left( \frac{1000 \times {TravelSpeed}}{2} \right)}}$

In certain embodiments, the predetermined value for efficiency may takeinto account any detected spatter, which may be determined using thetechniques disclosed in “Devices and Methods for Analyzing SpatterGenerating Events”, U.S. patent application Ser. No. 2013/0262000, filedon Mar. 30, 2012 in the name of Richard Martin Hutchison et al., whichis hereby incorporated into its entirety. For example, the predeterminedvalue of efficiency may be adjusted to, for example, lower thepredetermined value of efficiency when more spatter generating eventsare determined to occur, increase the predetermined value of efficiencywhen fewer spatter generating events are determined to occur, and soforth.

As used herein, the term “predetermined range” may mean any of thefollowing: a group of numbers bounded by a predetermined upper limit anda predetermined lower limit, a group of number greater than apredetermined limit, and a group of numbers less than a predeterminedlimit. Moreover, the range may include numbers equal to the one or morepredetermined limits.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

1. A welding system comprising: one or more cameras configured to detecta plurality of sets of visual markers of a welding device, wherein eachset of visual markers comprises visual markers oriented in a respectivemarker direction; and a controller coupled to the one or more cameras,wherein the controller is configured to: determine one or more markerdirections of one or more respective sets of visual markers of theplurality of sets of visual markers based at least in part on a detectedset of visual markers of the plurality of sets of visual markers; selectone of the sets of visual markers of the plurality of sets of visualmarkers as a tracked set of visual markers based at least in part on adetermined marker direction of the tracked set of visual markers;associate a rigid body model to the tracked set of visual markers; anddetermine a position and an orientation of the welding device based onthe associated rigid body model of the tracked set of visual markers. 2.The welding system of claim 1, wherein the one or more cameras comprisesa light source configured to emit light towards the welding device, andone or more of the visual markers is configured to reflect the emittedlight towards lenses of the one or more cameras when the respectivemarker direction of the one or more visual markers is oriented towardsthe one or more cameras.
 3. The welding system of claim 1, wherein therespective marker direction of the tracked set of visual markers isoriented toward the one or more cameras more than the marker directionsof other sets of visual markers of the plurality of sets of visualmarkers.
 4. The welding system of claim 1, wherein the controllerselects the tracked set of visual markers from the plurality of sets ofvisual markers based at least in part on a continuous duration that theone or more cameras detects the tracked set of visual markers, whereinthe continuous duration is greater than 200 milliseconds.
 5. The weldingsystem of claim 1, wherein the controller is configured to remainlatched to the tracked set of visual markers when the determined markerdirection of the tracked set of visual markers is within a latch anglethreshold of a line of sight to the one or more cameras.
 6. The weldingsystem of claim 1, wherein each detected set of visual markers comprisesthree or more visual markers.
 7. The welding system of claim 1, whereinthe plurality of sets of visual markers comprise light emitting diodes(LEDs) configured to emit light in the respective marker directions. 8.The welding system of claim 7, wherein the controller is configured toturn on LEDs of the selected set of visual markers sets and to turn offLEDs of other sets of visual markers of the plurality of sets of visualmarkers.
 9. The welding system of claim 1, wherein the controller isconfigured to determine welding parameters of the welding device basedon the determined position and the determined orientation of the weldingdevice.
 10. The welding system of claim 9, wherein the controller isconfigured to record in a non-transitory, computer readable memory thedetermined welding parameters of the welding.
 11. A welding systemcomprising: a welding torch, comprising: a first set of at least threelight emitting diodes (LEDs) oriented in a first marker direction; and asecond set of at least three LEDs oriented in a second marker direction;one or more cameras configured to detect light emitted from the LEDs ofthe first set of LEDs or the second set of LEDs when the respectivemarker direction is oriented toward the one or more cameras; and acontroller coupled to the one or more cameras, wherein the controller isconfigured to: detect a first rigid body model of the first set of LEDswhen the first marker direction is oriented toward the one or morecameras; detect a second rigid body model of the second set of LEDs whenthe second marker direction is oriented toward the one or more cameras;determine a position and an orientation of the welding torch based on adetected rigid body model, wherein the detected rigid body modelcomprises the first rigid body model or the second rigid body model;determine welding parameters of the welding torch based on the positionand the orientation of the welding torch; and record the weldingparameters of the welding torch during a welding operation in anon-transitory, computer readable memory.
 12. The welding system ofclaim 11, wherein the welding torch comprises a third set of at leastthree LEDs oriented in a third marker direction, wherein the one or morecameras is configured to detect light emitted from the LEDs of the thirdset of LEDs when the third marker direction is oriented toward the oneor more cameras, wherein the controller is configured to detect a thirdrigid body model of the third set of LEDs when the third markerdirection is oriented toward the one or more cameras, the controller isconfigured to determine the position and the orientation of the weldingtorch based on the detected rigid body model, and the detected rigidbody model comprises the first rigid body model, the second rigid bodymodel, or the third rigid body model.
 13. The welding system of claim11, wherein the controller is configured to selectively control thefirst set of LEDs and the second set of LEDs during the weldingoperation to emit light from only one of the first set of LEDs and thesecond set of LEDs at a time.
 14. The welding system of claim 11,wherein the controller is configured to determine the position and theorientation of the welding torch based on the determined first rigidbody model when the first marker direction is oriented toward the one ormore cameras more than the second marker direction, and the controlleris configured to determine the position and the orientation of thewelding torch based on the determined second rigid body model when thesecond marker direction is oriented toward the one or more cameras morethan the first marker direction.
 15. The welding system of claim 11,wherein the controller is configured to change the determination of theposition and the orientation based on the first rigid body model to bebased on the second rigid body model only when the first markerdirection is oriented more than a latch threshold angle relative to aline of sight to the one or more cameras and the second marker directionis oriented less than the latch threshold angle relative to the line ofsight to the one or more cameras, and the controller is configured tochange the determination of the position and the orientation based onthe second rigid body model to be based on the first rigid body modelonly when the second marker direction is oriented more than the latchthreshold angle relative to the line of sight to the one or more camerasand the first marker direction is oriented less than the latch thresholdangle relative to the line of sight to the one or more cameras.
 16. Thewelding system of claim 11, wherein the controller is configured tocontrol which of the first rigid body model and the second rigid bodymodel is utilized to determine the position and the orientation of thewelding torch using a hysteresis control based on the first markerdirection, the second marker direction, a latch threshold angle, and thedetected rigid body model.
 17. The welding system of claim 11, whereinthe controller is configured to determine the first marker directionbased at least in part on the detected first rigid body model when thefirst marker direction is oriented toward the one or more cameras, andthe controller is configured to determine the second marker directionrelative to the first marker direction.
 18. A method comprising:detecting, via one or more cameras, a first set of visual markers of aplurality of sets of visual markers coupled to a welding device, whereineach set of visual markers comprises visual markers oriented in arespective marker direction; determining one or more marker directionsof one or more respective sets of visual markers of the plurality ofsets of visual markers based at least in part on the detected first setof visual markers of the plurality of sets of visual markers; selectingone of the sets of visual markers of the plurality of sets of visualmarkers as a tracked set of visual markers based at least in part on adetermined marker direction of the tracked set of visual markers;associating a rigid body model to the tracked set of visual markers;determining a position and an orientation of the welding device based onthe associated rigid body model of the tracked set of visual markers;determining welding parameters of the welding device during a weldingoperation based on the determined position and the determinedorientation of the welding device; and recording the welding parametersin a non-transitory, computer readable memory.
 19. The method of claim18, comprising: detecting, via the one or more cameras, a second set ofvisual markers of the plurality of sets of visual markers coupled to thewelding device; and selecting the set of visual markers as the trackedset of visual markers based at least in part on a determined firstmarker direction of the first set of visual markers and a determinedsecond direction of the second set of visual markers.
 20. The method ofclaim 19, wherein selecting the set of visual markers as the tracked setof visual markers comprises utilizing a hysteresis control based on thedetermined first marker direction, the determined second markerdirection, a latch threshold angle, and the associated rigid body modelof the tracked set of visual markers.
 21. The method of claim 18,wherein the visual markers of the first set of visual markers compriselight emitting diodes (LEDs).
 22. The method of claim 18, comprising:associating a first rigid body model to the first detected set of visualmarkers of the plurality of sets of visual markers; and determining afirst marker direction of the first set of visual markers relative tothe first rigid body model of the first set of visual markers based atleast in part on a relative position of two or more visual markers ofthe first set of visual markers.
 23. The method of claim 18, comprising:detecting, via the one or more cameras, two or more secondary visualmarkers distinct from the first set of visual markers; associating afirst rigid body model to the first detected set of visual markers ofthe plurality of sets of visual markers; and determining a first markerdirection of the first set of visual markers relative to the first rigidbody model of the first set of visual markers based at least in part ona relative position of the two or more secondary visual markers.
 24. Themethod of claim 17, wherein the welding operation comprises a live arcwelding operation.
 25. A method comprising: turning on a first set oflight emitting diodes (LEDs) oriented in a first marker direction for afirst detection interval, wherein the first set of LEDs is disposed on awelding device; determining a first rigid body model of the first set ofLEDs if one or more cameras detects the first set of LEDs within thefirst detection interval, wherein the first rigid body model is based onthe detected arrangement of the first set of LEDs; turning on a secondset of LEDs oriented in a second marker direction for a second detectioninterval if the first set of LEDs is not detected by the one or morecameras within the first detection interval; and determining a secondrigid body model of the second set of LEDs if the one or more camerasdetects the second set of LEDs within the second detection interval,wherein the second rigid body model is based on the detected arrangementof the second set of LEDs.
 26. The method of claim 25, comprisingcontrolling the first set of LEDs and the second set of LEDs so thatonly the first set of LEDs emits light during the first detectioninterval and only the second set of LEDs emits light during the seconddetection interval.
 27. The method of claim 25, wherein the firstdetection interval and the second detection interval are less thanapproximately 500 ms.
 28. The method of claim 25, comprising: turning ona third set of LEDs oriented in a third marker direction for a thirddetection interval if the second set of LEDs is not detected by the oneor more cameras within the second detection interval; and determining athird rigid body model of the third set of LEDs if the one or morecameras detects the third set of LEDs within the third detectioninterval, wherein the third rigid body model is based on the detectedarrangement of the third set of LEDs.
 29. The method of claim 25,comprising repeating a cycle of turning on the first set of LEDs for thefirst detection interval and turning on the second set of LEDs for thesecond detection interval until the one or more cameras detects at leastone of the first set of LEDs and the second set of LEDs.
 30. The methodof claim 25, wherein each of the first set of LEDs and the second set ofLEDs comprises three or more LEDs, and the respective rigid body modelsare based at least in part on detection of at least three LEDs of eachrespective set of LEDs.